Question: A gauge repeatability and reproducibility study was

> Place write, Inc., an independent outplacement service, helps unemployed executives find jobs. One of the major activities of the service is pre paring resumes. Three word processors work at the service typing resumes and cover letters. Together they han

> Multisigma Corp. has a process they believe is operating near a six-sigma level and want to verify this. If the specification for a critical part in the process is 2.80 cm 6 0.10 and the standard deviation for the process is 0.02, at what sigma level is

> The Excel workbook C08 Problem Data provides data on quality losses at Sonoco Paper Mill. Find the percentage of cost for each category, and the cumulative percentages when the categories are sorted by decreasing costs. Construct an appropriate Excel cha

> The Morelia Mortgage Company (MMC) is a mediumsized mortgage lender that has continued to do well, despite the “meltdown” in the mortgage lending industry. Prior to the economic downturn, MMC was a principal supplier of lending services to Southwestern D

> Reship Solutions, Inc. has a distribution center in Cincinnati where it receives and breaks down bulk orders from suppliers’ factories and ships out products to retail customers. Prepare a pie or bar chart showing the different quality cost categories an

> Compute a labor cost base index for the data in the Excel workbook C08 Problem Data for Miami Valley Aircraft Service Co. Analyze the quality cost information and prepare a memo to management explaining your conclusions. (See the supplementary reading Qu

> Classify the cost elements for the Impressive Printing Company in the Excel workbook C08 Problem Data into the proper quality cost categories and find the total quality cost by category and percentage of total quality cost by category. Prepare a pie char

> Determine, using Figure 8.50, the appropriate sample size for detecting: a. A 1-sigma shift in the mean with a 0.80 probability b. A 2-sigma shift with 0.95 probability c. A 2.5-sigma shift with 0.90 probability

> Analyze the cost data in the Excel workbook C08 Problem Data for the Cost-cutting Co. Create a chart to help you explain the results. What are the implications of these data for management?

> Top Billers processes bills for customers. Bills can contain errors due to a number of causes, such as incorrect amounts, wrong dates, wrong customer information, etc. The quality manager for Top Billers decided to examine all bills processed over 25 wee

> A quality consultant was asked to analyze the data from order errors at the Audubon Books, Inc., distribution center as shown in the C08 Problem Data workbook. Any order can have one or more errors such as wrong item, incorrect customer information, etc.

> Pharma Express, Inc., a mail-order prescription drug vendor, measured the number of errors per standard 200-line order being picked in their distribution center as provided in the C08 Problem Data workbook. Compute the control limits for a c-chart using

> Federal Scanline, Inc. uses a scanner on a conveyor line that scans 1,000 packages per hour. Packages which have defective labels or detectable damage to the package are automatically offloaded and handchecked. Defects might be a number missing from a zi

> Construct an np-chart for the Dennis Manufacturing Company using the data in the C08 Problem Data workbook and the np-chart Excel template. The data represent the number of defective parts found in 30 samples, each of size 50. Explain the results.

> The Joint Commission on Accreditation of Healthcare Organizations (JCAHO) monitors and evaluates health care providers according to strict standards and guidelines. Improvement in the quality of care is a principal concern. Hospitals are required to iden

> Compute the control limits for an np-chart using the data in Problem 42 for the Full Life Insurance Co. using the appropriate formulas. Then verify your calculations using the np-chart Excel template. Explain the relationship between the control limits f

> The manager of a customer service call center is concerned that the level of access of customers is decreasing due to heavier use. The proportion of peak period time when a customer is likely to quickly connect to a representative without waiting is cons

> One hundred insurance claim forms are inspected daily at Full Life Insurance Co. over 25 working days, and the number of forms with errors has been recorded as shown in the C08 Problem Data workbook. Construct a p-chart using the Excel template. If any p

> Samples of package orders were taken at the Altodiez Package Co. to determine if the orders were prepared correctly. The number of orders with errors for each of 25 days are given in the C08 Problem Data workbook. Two hundred orders are inspected each da

> Thirty samples of 100 items each were inspected at the Rummy Candy Company and 150 items were found to be defective. Compute control limits for a p-chart for this process.

> Boardwalk Electronics manufactures 300,000 circuit boards per month. A random sample of 3,000 boards is inspected every week for five characteristics. During a recent week, three defects were found for one characteristic, and two defects each were found

> Charlie’s China Emporium sells a variety of imported items at a seaside resort. The store owner wants to monitor daily sales, which are provided for 75 days in the C08 Problem Data workbook. Use the X&MR Excel template to construct an x- and moving range

> Chief Henry Batter of the Gotham City Police Department is trying to reduce the time required to answer the phone at police headquarters (in fractions of a minute). The data are provided in the C08 Problem Data workbook, and represent time in fractions o

> Calculate the process capability statistics for the outside diameters of the bottles made on the injection molding machine at the Moby Molding Co. in Problem 36. Use the Process Capability Excel template with 0.1 as the upper tolerance limit and 20.05 as

> An injection molding machine at the Moby Molding Co. used to make plastic bottles has four molding heads. The outside diameter of the bottle is an important measure of process performance. The C08 Problem Data workbook provides results from 30 samples in

> Food and Drug Administration (FDA) is the primary regulatory agency for businesses that operate in food service industries. Product quality and safety are the FDA’s primary concern and there are very strict guidelines a company must fol

> El Grande Toro Restaurant advertises that customers will have their orders taken within three minutes after being seated. Management wants to monitor these times, as it is such an important guarantee for business. Forty samples of size 5 can be found in

> Fujiyama Electronics wants to construct x- and s-charts for circuit boards that are purchased from an outside supplier. A critical dimension is the distance between two holes on the board that are supposed to be 5 cm apart. Use the data in the C08 Proble

> Constant Hope Hospital wants to set up x and s control charts for the time required to perform a critical step in gall bladder surgery. Twenty-five samples of size 4 can be found in the C08 Problem Data workbook. Find the control limits using the appropr

> Drives has a statistically in-control manufacturing process that is normally distributed. Sample means and ranges for 15 samples of size 5 can be found in the C08 Problem Data workbook. Determine process capability indexes by estimating the standard devi

> For each of the control charts in Figure 8.56, assume that the process has been operating in statistical control for some time. What conclusions should the operators reach at this point?

> The initial data provided in the Excel workbook C08 Problem Data represent processing time values for 20 samples of size 4 that were taken from Rapid Check Kiters, Inc., a check processing firm, over a 20-hour period. a. Use the X-bar&R Excel template t

> Nighthawk Airlines measured their numbers of lost bags in one month and found that they had lost 35 bags for 10,000 customers. If the average number of bags per customer is 1.2, how many errors per million opportunities (tempo) does this represent? The w

> Use the data for Birdseye Magnetrons (Problem 24) and the X-bar&R Excel template to determine if the process appears to be in statistical control. Data from problem 24: Birdseye Magnetrons makes induction meters used in vending machines to test the vali

> Hermitage DNA Labs, LLC collected temperature readings in an analysis process. The data can be found in the C08 Problem Data workbook. a. Compute the mean and range of each sample and calculate control limits for x and R charts using the appropriate for

> J. McWilliams Swim Club is trying to calibrate its chlorine pump to ensure that the right amount of chlorine (1.0–1.5 ppm of free chlorine) is mixed into the water. Thirty samples of four readings at random times during the week were taken. These data ca

> Black Elk Medical Center (BEMC) is a qualitydriven acute care hospital organization that includes three medical facilities that treat both inpatients and outpatients. BEMC has won numerous national and local quality awards. These included the J.D. Power

> After some further analysis, River Bottom Fire Department (Problem 22) relocated one of their fire stations. After doing so, they wanted to evaluate response times to determine whether or not the response process was in control. Thirty new samples were t

> Twenty-five samples of size 4 resulted in statistics of x 5 38.0 minutes and R 5 3.0 minutes for the Turk master Cleaning Company’s average time to completely clean a rug. Compute control limits for x- and R-charts and estimate the standard deviation of

> Birdseye Magnetrons makes induction meters used in vending machines to test the validity of coins. Their specifications require the induction reading capability of the meters to fall between 0.25 and 0.50 Tesla (T) units. Quality analysts took 3 random t

> Palma State Bank is investigating the processing time for loan applications. Samples were taken for 25 random days from 5 branches. These data can be found in the C08 Problem Data workbook. a. Compute the mean and standard deviation, and construct a hist

> River Bottom Fire Department is evaluating their response times in order to determine whether a new fire station is needed. Samples were taken for 30 consecutive days from 6 stations. These data can be found in the C08 Problem Data workbook. a. Compute

> Suppose that a refrigeration process at Cold foods, Ltd. Has a normally distributed output with a mean of 27.0 and a variance of 1.21. a. If the specifications are 27.0 6 3.25, compute b. Suppose the mean shifts to 26.0 but the variance remains unchange

> Samples for three parts made at River City Parts Co. were taken and provided in the C08 Problem Data workbook. a. Calculate the mean and standard deviation for each part and compare the natural variation of each part to the following specification limit

> Well place Insurance Company processes insurance policy applications in batches of 50. One day, they had 10 batches to process and, after inspection, it was found that 4 batches had nonconforming policies. One batch had 3 nonconformances, another had 5,

> From the data for Saami Theatrical Products that can be found in the C08 Problem Data workbook, use the Process Capability Excel template to find a histogram and compute the process capability indexes. If the specifications are 22 6 0.03, estimate the pe

> A machining process at the Mach4 Tool Co. has a required dimension on a part of 0.575 6 0.007 inch. Dimensions of 25 parts were measured and are available in the C08 Problem Data workbook. a. Compute the process capability indexes using formulas (8.25) t

> This case is based on an application of QFD at Tennessee Technological University to their Research Resources Center (RRC), an internal service system. Originally created as a support facility for faculty and student research, the RRC has grown to offer

> Use formulas (8.26) and (8.27) to show mathematically that when the process mean is centered

> A gauge repeatability and reproducibility study at Frankford Brake Systems collected the data found in the worksheet Prob. 8-15 in the Excel file C08Data.xlsx on the Student Companion Site for this chapter. Analyze these data. The part specification is 1

> A gauge repeatability and reproducibility study at New Gauge, Inc., collected data for three operators, two trials, and eight parts, available in the C08 Problem Data worksheet. The part specification is 1.5 6 0.1 inches. Use formulas (8.6) through (8.24

> Two scales at Aussieburgers, Ltd. were used to weigh the same 25 samples of hamburger patties for a fast food restaurant in Australia. Results are shown in the C08 Problem Data workbook. The samples were weighed in grams, and the supplier has ensured tha

> A genetic researcher at Gelb, Ltd. is trying to test two laboratory thermometers (that can be read to 1/100,000th of a degree Celsius) for accuracy and precision. She measured 25 samples with each and obtained the results found in the C08 Problem Data wo

> Analyze the quality losses at Beech ware Software Corp. using the data in the Excel workbook C08 Problem Data. What conclusions do you reach?

> Stateside Metrology Repairs, Inc. has a thriving business repairing and upgrading high-technology measuring instruments. The costs of quality that they have collected over the past year can be found in the Excel workbook C08 Problem Data. Analyze their q

> Leatherlike Manufacturing Company makes an artificial leather-like product for the fashion accessory market. The material is made in sheets and has the appearance of a thin rug. Each sheet is 36 inches wide and 100 feet long and is wound into a roll. The

> A team was formed to study the auto part at Adams Metal Fabricating described in Problem 8. While continuing to work to find the root cause of scrap, the team found a way to reduce the cost for scrapping the part to $45 per part. a. Determine the Taguch

> In a true story related by our colleague Professor James W. Dean, Jr., the general manager of an elevator company was frustrated with the lack of cooperation between the mechanical engineers who designed new elevators and the manufacturing engineers who

> A specification for the length of an auto part at Adams Metal Fabricating is 15.0 6 1.75 centimeters (cm). It costs $65 to scrap a part. Determine the Taguchi loss function. Then, determine the expected loss if the process mean is found to be 15.03 cm wi

> A team was formed to study the refrigerator part at Cool Food, Inc. described in Problem 6. While continuing to work to find the root cause of scrap, they found a way to reduce the scrap cost to $35 per part. a. Determine the Taguchi loss function for t

> A blueprint specification for the thickness of a refrigerator part at Cool Food, Inc. is 0.06 6 0.04 centimeters (cm). It costs $45 to scrap a part that is outside the specifications. Determine the Taguchi loss function for this situation.

> Georgia’s Giant Gyros (Problem 4) acquired some additional information about product characteristics. It found that consumers placed the highest importance on taste appeal (especially flavor), followed by healthiness (measured by sodium content and calor

> Georgia’s Giant Gyros conducted consumer surveys and focus groups concerning a new gyro sandwich design and the restaurant facility, and identified the most important customer expectations (not in any order of priority) as: Tasty, attractive, moderately

> National Partamiento installs and maintains thousands of refrigerators and other appliances in rental apartments across the country. They have conducted a short study of failure rates based on following the performance of 25,440 refrigerators that were i

> Newtonian, Inc. (Problem 2) faces three major competitors in this market: Oldphonia, Symphonic, and Collie onia. It found that potential consumers placed the highest importance on reliability (measured by such things as freedom from operating system cras

> Mega art, a large department store, has a very successful and profitable package-wrapping department. The department uses two complex bow-making machines that work inline to make the bows for the packages. Bow-making Machine 1 has a reliability of 0.97.

> An automated production system at Autopsy’s Inc. consists of three operations: turning, milling, and grinding. Individual parts are transferred from one operation to the next by a robot. Hence, if one machine or the robot fails, the process stops. A prod

> Maniple, Inc. has a complex manufacturing process, with three operations that are performed in series. Because of the nature of the process, machines frequently fall out of adjustment and must be repaired. To keep the system going, two identical machines

> Many one-tenth scale remote control (RC) model car racing enthusiasts believe that spending more money on high-quality batteries, using expensive gold-plated connectors, and storing batteries at low temperatures will improve battery life performance in a

> Getronics has a three-step process for processing customer sales. First, the cashier must look up the customer’s loyalty card on the company’s information system. Second, the cashier enters the transaction on the point-of-sale register. Third, the cashie

> An electronic missile guidance system at Guide, Inc. consists of Components A, B, C, and D, which have reliabilities of 0.98, 0.97, 0.91, and 0.95, respectively (see the following diagram). a. What is the reliability of the entire system? b. Suppose th

> A manufacturer of electric cooktops purchases major electronic components as modules. The reliabilities of components differ by supplier (see the system diagram below). Suppose that the configuration of the major components is given by: The components c

> The MTBF of an integrated circuit made by Way forward, Inc. is 16,000 hours. Calculate the failure rate.

> An electronic component in a satellite radio made by Space scope, Inc. has a failure rate of λ = 0.0000165 units/hour. Find the mean time to failure (MTTF). What is the probability (assuming an exponential probability distribution) that the component wil

> Livelong, Inc.’s computer monitors have a failure rate of λ = 0.00095 units per hour. Assuming an exponential distribution, what is the reliability function? What is the probability of failure within 2,000 hours? Calculate your answer using the appropria

> Broadened, Inc. makes automobile tires that have a mean life of 50,000 miles with a standard deviation of 2,500 miles. Using Excel functions (see Chapter 6), determine the following: a. What fraction of tires is expected to survive beyond 54,000 miles?

> Newtonian, Inc. is working on a design for a new smartphone. Marketing staff conducted extensive surveys and focus groups with potential customers to determine the characteristics that the customers want and expect in a smartphone. Newtonian’s studies ha

> The life of a calorific phone battery is normally distributed with a mean of 1,100 days and standard deviation of 60 days. Using Excel functions (see Chapter 6), determine the following: a. What fraction of batteries is expected to survive beyond 1,200

> Massive Corporation’s tested five motors in a 900- hour test. Compute the failure rate if three failed after 200, 475, and 750 hours and the other two ran for the full 900 hours each.

> The Breton Card Company (BCC) is a manufacturer of playing cards and novelty cards for consumers and entertainment businesses. Playing cards are produced to individual specifications, which include the customer rolls of paper together, printing the ink p

> The average time to handle a call in the Call-No wait call processing center has a specification of 5.9 6 1.15 minutes. The loss due to a mishandled call is $15. A sample of 25 calls was drawn from the process and the results, in minutes, can be found in

> Two processes, P and Q, are used by a supplier to produce the same component, Z, which is a critical part in the engine of the Bearing Port 778 airplane. The specification for Z calls for a dimension of 0.24 mm 6 0.03. The probabilities of achieving the

> At Elproparts Manufacturers’ integrated circuit business, managers gathered data from a customer focus group and found that any output voltage that exceeds 60 6 3.5 volts was unacceptable to the customer. Exceeding these limits results in an estimated lo

> A computer chip designed by the MicroKeeb Co. has a specification for the distance between two adjacent pins of 2.000 6 0.002 mm. The loss due to a defective chip is $4. A sample of 25 chips was drawn from the production process and the results, in milli

> A computer chip designed by the MicroKeeb Co. has a specification for the distance between two adjacent pins of 2.000 6 0.002 mm. The loss due to a defective chip is $4. A sample of 25 chips was drawn from the production process and the results, in milli

> An automatic cookie machine at ACM, Inc. must deposit a specified amount of 25 6 0.3 grams (g) of dough for each cookie on a conveyor belt. It costs $0.03 to scrap a defective cookie. A sample of 50 cookies was drawn from the production process, which ha

> An electronic component at Amp comp has a specification of 100 6 0.4 ohms. Scrapping the component results in a $81 loss. a. What is the value of k in the Taguchi loss function? b. If the process at Amp comp averages 99.8 ohms with a standard deviation

> Guido Unlimited makes electronic soundboards for car stereos. Output voltage to a certain component on the board must be 12 6 0.5 volts. Exceeding the limits results in an estimated loss of $60. Determine the Taguchi loss function.

> A hospital developed a design process consisting of the following steps: Plan, Design, Measure, Assess, and Improve. Below is a list of specific activities that comprise these five steps in random order. Place the activities in the most appropriate order

> The dimension of a machined part made by Perfection Machining, Inc. has a nominal specification of 7.6 cm. The process that produces the part can be controlled to have a mean value equal to this specification, but has a standard deviation of 0.3 cm. What

> Nearly everyone has eaten at McDonald’s; the company sells millions of French fries each day. However, variation in the fries hasn’t gone unnoticed. One Japanese news source challenged McDonald’s Japanese weight standard with an experiment. Weighing 6500

> The mean time to pour and process 5 cubic yards of concrete by the Ohio Valley Construction is 15.5 minutes. If 2 percent of the projects with 5 yards of concrete require more than 15.75 minutes, what is the standard deviation of the time for such projec

> Sparkly Cleaning Co. has found that standard size offices have a standard deviation of 5 minutes for their cleaning time. The operations manager knows that 95 percent of the offices require more than 120 person-minutes to clean. However, she wishes to fi

> Frackly Oil is sold in 900 milliliter (mL) cans. The mean volume of oil placed in a can is 880 ml with a standard deviation of 7.8 mile Assuming a normal distribution of the data, what is the probability that the filling machine will cause an overflow in

> El Grande Green Tea is sold in 350 milliliter cans. The standard deviation for the filling process is 9 milliliters. What must the target mean for the process be to ensure that the probability of overfilling more than 350 mL in a can is at most 1 percent

> Rainbow Punch was made by Frutayuda, Inc. and sold in 12-ounce cans to benefit victims of Hurricane Zero. The mean number of ounces placed in a can by an automatic fill pump is 11.7 with a standard deviation of 0.18 ounce. Assuming a normal distribution,

> The Turk alike Rug Company buys medium grade carpet in 100-foot rolls. The average number of defects per roll is 2.0. Assuming that these data follow a Poisson distribution, use the Poisson spreadsheet template to answer the following questions. a. What

> Auditors at the Valles Verdes Partners, P.S.C. took a sample of 150 accounts payable bills, as shown in the table found in the Excel worksheet Prob. 6-2 in the Excel workbook C06 Problem Data. a. Find the proportion of the accounts payable in the sample

> A quality manager at Nevis Pharmaceutical Company is monitoring a process that fills vials with a liquid medication designed to prevent glaucoma in the eyes of the user. The company wants to ensure that each vial contains at least 60 mL (2.03 fluid oz.)

> Tessler Electric utility requires service operators to answer telephone calls from customers in an average time of 0.1 minute or less. A sample of 25 actual operator times was drawn, and the results are given in the following table. In addition, operator