A study has been initiated on a filling process.

The data represent the net weight in pounds for 20-pound

bags of dry cat food. The samples of n=5 represent 5 consecutive bags produced by a filling head of a
machine. The samples were collected at 30 minutes intervals. Ultimately, the goal is to fill the bags as
close as 20 pounds as possible without going under the nominal weight of 20 pounds. Regulations allow
only 0.1% of the bags to be below this value.

a) Use the data for days 1 and 2, construct a histogram and a probability plot. Comment on the
charts obtained.
Histogram of x
Normal

Mean
StDev
N

40

20.99
0.09802
150

Frequency

30

20

10

20.7

20.8

20.9

21.0
x

21.1

21.2

21.3

Probability Plot of x
Normal - 95% CI

99.9

Mean
StDev
N
AD
P-Value

99

Percent

95
90
80
70
60
50
40
30
20
10
5
1
0.1

20.6

20.7

20.8

20.9

21.0
x

21.1

21.2

21.3

21.4

20.99
0.09802
150
0.774
0.044

b) The first step in this study is to examine the filling process from a statistical control point of
view. Use the data for days1 and 2 to establish X and R chart for the process. Interpret the
charts.

Xbar-R Chart of X1, ..., X5

U C L=21.1130

Sample M ean

21.10
21.05

_
_
X=20.9944

21.00
20.95
20.90

LC L=20.8758
1

10

13

16
Sample

19

22

25

28

0.48

Sample Range

U C L=0.4349
0.36
_
R=0.2057

0.24
0.12
0.00

LC L=0
1

Sample
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Day
1
1
1
1
1
1
1
1
1
1
1
1
1
1

X1
20.97
20.99
20.99
20.88
20.87
21.08
20.70
20.89
21.01
20.95
21.10
21.02
21.00
20.96

10

13

X2
21.03
20.88
21.00
21.09
21.08
20.99
21.20
20.99
20.90
21.01
20.96
21.05
20.87
21.03

16
Sample

X3
21.09
20.89
20.95
21.05
20.99
21.18
20.97
21.02
20.97
21.09
21.02
21.03
21.00
21.03

19

X4
21.04
20.94
21.00
21.05
20.97
21.02
20.84
20.95
21.09
21.10
21.03
20.99
21.05
21.11

22

25

X5
20.94
20.99
20.90
21.01
21.04
21.07
21.01
20.99
21.13
21.10
21.01
21.08
20.97
21.05

28

x-bar
21.0140
20.9380
20.9680
21.0160
20.9900
21.0680
20.9440
20.9680
21.0200
21.0500
21.0240
21.0340
20.9780
21.0360

R
0.15
0.11
0.10
0.21
0.21
0.19
0.50
0.13
0.23
0.15
0.14
0.09
0.18
0.15

15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

21.15
20.98
20.95
20.98
20.89
21.16
21.10
20.83
20.98
20.95
21.04
20.98
20.80
21.04
20.94
20.91

20.84
20.85
20.92
20.98
20.90
20.96
20.87
20.75
21.02
20.88
20.95
20.96
20.99
21.00
21.02
21.30

21.02
20.89
20.95
21.01
21.05
20.96
20.95
21.04
21.06
20.97
21.00
21.04
20.98
20.87
20.92
21.10

21.18
20.82
20.84
21.12
21.05
21.06
21.05
21.25
20.87
21.01
21.14
21.09
21.03
21.02
21.00
21.24

21.05
20.95
20.92
21.19
20.87
21.00
21.14
20.77
21.00
20.85
21.06
21.05
20.89
20.91
21.01
20.81

(Take 5 decimal values)

Mean X = X =

Mean R = R =

629.8320
=20.99440
30

6.17
0.20567
30

Control limits for X chart:

Centre Line = X =

629.8320
=20.999940
30

X + A2 R == 20.99440+ 0.577(0.20567) ==(20.87573, 21.11307)

Control limits for R-chart:

Center Line= R =

6.17
=0.20567
30

Lower Control Lower =D3 R =0(0.20567)=0

21.0480
20.8980
20.9160
21.0560
20.9520
21.0280
21.0220
20.9280
20.9860
20.9320
21.0380
21.0240
20.9380
20.9680
20.9780
21.0720
629.8320
20.99440

0.34
0.16
0.11
0.21
0.18
0.20
0.27
0.50
0.19
0.16
0.19
0.13
0.23
0.17
0.10
0.49
6.17
0.20567

Upper Control Limit = D4 R =2.114(0.20567)= 0.434779

c) If out of control conditions are present, assume that the physical cause is identified. Remove the
out-of-control subgroups and recalculate the center line and control limits. Continue until the
charts show good statistical chart control. State what out-of-control points indicate about the
process. Once in control, estimate the process mean and the process standard deviation.
Assuming fill follows a normal distribution, are we meeting regulations?

Xbar-R Chart of X1, ..., X5

Sample M ean

21.10

U C L=21.0958

21.05
_
_
X=20.9959

21.00
20.95
20.90

LC L=20.8959
1

10

13

16
Sample

19

22

25

28

Sample Range

0.48

U C L=0.3665

0.36
0.24

_
R=0.1733

0.12
0.00

LC L=0
1

Sample
1
2
3
4
5
6
7
8
9
10

Day
1
1
1
1
1
1
1
1
1
1

X1
20.97
20.99
20.99
20.88
20.87
21.08
20.70
20.89
21.01
20.95

10

13

X2
21.03
20.88
21.00
21.09
21.08
20.99
21.20
20.99
20.90
21.01

16
Sample

X3
21.09
20.89
20.95
21.05
20.99
21.18
20.97
21.02
20.97
21.09

19

X4
21.04
20.94
21.00
21.05
20.97
21.02
20.84
20.95
21.09
21.10

22

25

X5
20.94
20.99
20.90
21.01
21.04
21.07
21.01
20.99
21.13
21.10

28

x-bar
21.0140
20.9380
20.9680
21.0160
20.9900
21.0680
0.0000
20.9680
21.0200
21.0500

R
0.15
0.11
0.10
0.21
0.21
0.19
0.00
0.13
0.23
0.15

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

21.10
21.02
21.00
20.96
21.15
20.98
20.95
20.98
20.89
21.16
21.10
20.83
20.98
20.95
21.04
20.98
20.80
21.04
20.94
20.91

20.96
21.05
20.87
21.03
20.84
20.85
20.92
20.98
20.90
20.96
20.87
20.75
21.02
20.88
20.95
20.96
20.99
21.00
21.02
21.30

21.02
21.03
21.00
21.03
21.02
20.89
20.95
21.01
21.05
20.96
20.95
21.04
21.06
20.97
21.00
21.04
20.98
20.87
20.92
21.10

21.03
20.99
21.05
21.11
21.18
20.82
20.84
21.12
21.05
21.06
21.05
21.25
20.87
21.01
21.14
21.09
21.03
21.02
21.00
21.24

21.01
21.08
20.97
21.05
21.05
20.95
20.92
21.19
20.87
21.00
21.14
20.77
21.00
20.85
21.06
21.05
20.89
20.91
21.01
20.81

(Take 5 decimal values)

Mean X = X =

Mean R = R =

566.8880
=20.99585
27

4.68
0.17333
27

Control limits for X chart:

Centre Line = X =

566.8880
=20.99585
27

X + A2 R == 20.99585+ 0.577(0.17333) ==(20.8958, 21.0959)

21.0240
21.0340
20.9780
21.0360
21.0480
20.8980
20.9160
21.0560
20.9520
21.0280
21.0220
0.0000
20.9860
20.9320
21.0380
21.0240
20.9380
20.9680
20.9780
0.0000
566.8880
20.99585

0.14
0.09
0.18
0.15
0.34
0.16
0.11
0.21
0.18
0.20
0.27
0.00
0.19
0.16
0.19
0.13
0.23
0.17
0.10
0.00
4.68
0.17333

Control limits for R-chart:

Center Line= R =

4.68
=0.17333
27

Lower Control Lower =D3 R =0(0.17333)=0

Upper Control Limit = D4 R =2.114(0.17333)= 0.3664

20 20 .99585

P Z
P ( Z 13 .36 ) 1
0.07452

d) A group is formed to study the process further with the hopes of reducing the known variation
in the process. It is determined the most likely cause of variation centered around the fact that
adjustments were made assuming a much smaller practical size than actually was present in the
cat food. We address this common cause problem and change the process. Data are collected
for a day 3. Use X and R charts to assess the process change. You might want to stage the data
showing difference before and after process change. Can you specify an economic advantage
associated with the process change?

Xbar-R Chart of X1, ..., X5 by Day

1

Sample M ean

21.10

21.05
U C L=21.0297
_
_
X=20.9951

21.00

LC L=20.9605

20.95
20.90
1

13

17

21
25
Sample

29

0.48
Sample Range

33

37

41

45

0.36
0.24
U C L=0.1269
_
R=0.06
LC L=0

0.12
0.00
1

13

17

21
25
Sample

29

33

37

41

45