Get Instant Help From 5000+ Experts For

Writing: Get your essay and assignment written from scratch by PhD expert

Rewriting: Paraphrase or rewrite your friend's essay with similar meaning at reduced cost

Designing a Quality Improvement Program and Applying Statistical Process Control

## Section A: Statistical Process Control (SPC) Theory

Design a quality improvement program, select and identify suitable tools and techniques. Discuss the importance of performance measurement and explain how performance measurement system, benchmarking, and other techniques can help a company achieve continuous improvement.

Compare the different approaches to quality costing and evaluate the effectiveness of these methods.

1. Your process has a normal histogram with mean located at 10 mm, 1s points at 9.9 and 10.1 mm, 2s points at 9.8 and 10.2 mm, and 3s points at 9.7 and 10.3 mm.

a. Construct a histogram and discuss the importance of sigma as a measure of variation. (8 marks)

b. If your customer will accept parts measuring between 9.7 and 10.3 mm, how many parts of every 1,000 produced would you expect to scrap? What would have to be done to bring the scrap rate down to what it had been at the former customer specification? (7 marks)

2. What is “Goalpost Mentality”? Why does it give producers false hope that they are satisfying their customers? What is a better way of looking at your performance capability? (10 marks)

3. In developing a control chart, the analyst recognizes that there are two types of variation in a system. Specify the types of variation. Explain the difference and what should be done to eliminate these variations (5 marks)

4. The following results were obtained by taking samples of five (5) items at regular intervals.

 Sample # observation 1 74.030 74.002 74.019 73.992 73.999 2 73.989 74.000 73.992 73.995 74.000 3 73.998 74.002 74.05 73.989 74.030 4 74.005 74.030 73.995 74.000 73.990 5 74.006 73.990 74.004 73.998 74.002 6 73.982 73.984 73.998 73.999 73.995 7 74.003 74.002 74.008 73.992 73.999 8 73.989 74.001 74.001 73.998 74.000 9 73.998 74.002 74.001 73.989 74.030 10 74.005 74.021 73.995 73.990 73.993 11 74.004 73.995 74.004 73.998 74.002 12 73.982 73.984 73.998 73.999 73.995 13 74.006 73.998 74.005 73.998 74.000 14 73.998 73.995 73.998 73.982 74.006 15 74.000 74.005 73.982 73.998 74.006 16 73.998 74.030 73.998 74.000 74.002 17 74.005 74.006 73.995 74.000 73.998 18 74.006 73.998 74.000 74.030 73.982 19 74.005 73.998 74.006 74.005 73.998 20 73.998 73.993 73.995 74.006 74.005

a) Construct control charts for the sample means and ranges showing the control limits and comment on the results.

 When sample size (n) 2 3 4 5 A2 1.88 1.023 0.729 0.577 D2 1.128 1.693 2.059 2.326 D3 0 0 0 0 D4 3.268 2.574 2.282 2.114

b) The specification asks for a tolerance of 74inch +/- .04inch.  Calculate the process capability indices Cp and Cpk and comment on these. What level of process capability should you strive to achieve for Cp and Cpk. (10 marks)

Explain variation, apply SPC to a simple example and calculate process capability. Plan the implementation of SPC in a manufacturing organization.

You are the Quality Manager in an electric car manufacturing company and feel it is time to implement some form of improvement programme. Describe your recommendations in a report to the Directors, which must include:

1. A method for implementing SPC across the company, including pre-requisites for implementation, the implementation process and procedures to follow to ensure that the benefits of SPC can be achieved. This should be in the form of a flow chart with an additional 1 page justification. (20 marks)

2. A summary of one relevant tool/technique which could be applied alongside statistical process control and its benefits. (10 marks)

3. Select a quality costing method and analyse the benefits this technique could bring to the company and also evaluate any issues with the quality costing method. (10 marks)

4. Overall structure and clarity of the report (10 marks)