Statistical Process Control

Cases and Problems

Logitech company Problem
Day No of
Defectives
Day No of
Defectives
Day No of
Defectives
1 3 8 7 15 7
2 10 9 18 16 6
3 13 10 1 17 19
4 4 11 0 18 3
5 12 12 4 19 9
6 14 13 9 20 7
7 8 14 22
A sample of 50 disks per day is inspected
Case Question
Production manager suspects the variation was due to
substitution of an inexperienced candidate instead of
regular one on 3 days during the period.
Indigo airlines Problem
In Indigo aircraft's landing gear assembly the defects are
detected as given in the table below
If the weightages given for the different classes of defects
are A=10, B=5, and C=1. construct appropriate control
chart for quality.
Plotting on a graph sheet.


Scale
Please note:
In end semester examination, if you are asked to draw/solve a control chart problem,
please use 6 sigma limits only,(do not use 3 sigma control limit (1.5 sigma + 1.5 sigma) or
you will loose marks).
Even if the question tells you to draw 3 sigma control limits, please understand that you
are expected to draw 6 sigma control limits( 3sigma + 3 sigma).
Case study : Scharadin Hotels
National hotel chain started in 1957 by Milo Scharadin.
Highly reputable national hotel chain
Serve over 100 1ocations and are recognized for their customer
service and quality.
They cater to both business and nonbusiness customers
A Problem with Quality
Scharadin Hotel in San Antonio, Texas, had recently been experiencing a large
number of guest complaints due to billing errors.
Guest complaints ranged from extra charges, such as meals or services that were
not purchased, to confusion for not being charged at all
The hotel staff often had to calm frustrated guests who were rushing to the airport
and were aggravated that they were getting charged for items they had not
purchased.
Staff meeting discussion
Larraine Scharadin, Milo Scharadins niece - recent business school graduate
new computer system and software
Tim Coleman, head of MIS, defended the system
Tim claimed that a few hotel guests made an issue of a few random problems.
Scott Schultz, head of operations, was not so sure.
Scott said that he noticed that the number of complaints seem to have
significantly increased since the new system was installed.
Audit of 50 random bills per day over the
past 30 days.
Tim exclaimed: Notice that the number of errors increases in the
last third of the month. The computer system had been in place for
the entire month so that cant be the problem. Scott, it is probably
the new employees you have on staff that are not enteringthe
data properly.
Scott quickly retaliated: The employees are trained properly!
Everyone knows the problem is the computer system!
Case Questions
1. Set up three-sigma control limits with the given data.
2. Is the process in control? Why?
3. Based on your analysis do you think the problem is the new
computer system or something else?
4. What advice would you give to Larraine based on the information
that you have?
2006 Prentice Hall, Inc. S6 14
Patterns in Control Charts
Normal behavior.
Process is in control.
Upper control limit
Target
Lower control limit
Figure S6.7
2006 Prentice Hall, Inc. S6 15
Upper control limit
Target
Lower control limit
Patterns in Control Charts
One plot out above (or
below). Investigate for
cause. Process is out
of control.
Figure S6.7
2006 Prentice Hall, Inc. S6 16
Upper control limit
Target
Lower control limit
Patterns in Control Charts
Run of 5 above (or
below) central line.
Investigate for cause. Figure S6.7
2006 Prentice Hall, Inc. S6 17
Upper control limit
Target
Lower control limit
Patterns in Control Charts
Erratic behavior.
Investigate.
Figure S6.7
Career in Quality
Six sigma Green Belt, Black Belt
Master black belt
ASQ or ISI
Lead auditor
Thank you