02 Sep Quality Management “Excel Sheet”
| Problem 1, 10 points | |||||
| The failure rate for a product is | 0.0000007396 | units per hour and the design engineers believe that it | |||
| is steady from 100 hours to 80,600 hours of product life. If you only wanted to replace | 0.0298226727 | proportion | |||
| of the product due to warranty claims: 1) how long would your warranty period be, 2) what would you do | |||||
| about the fact that the rate of failure is not steady until after 100 hours of operation, and 3) briefly, (one or two | |||||
| short sentences) discuss what else you would put in the warranty relative to reliability? | |||||
| Problem 2, 15 points | |||||
| Step 1 | Step 2 | Step 3 | Step 4 | ||
| 0.9705435508 | 0.974847562 | 0.9616032386 | 0.9882807136 | ||
| R10000 | R11000 | R12000 | R10000 | ||
| 0.9710617405 | |||||
| R9000 | |||||
| 0.9881977976 | |||||
| R10000 | |||||
| What is the R10000 reliability of the above system? A signal travels from left to right and, in step two, can go through any of the three | |||||
| units working in parallel. | |||||
| Problem 3, 38 points | 0.1723269773 | ||||
| Design engineers have set product specifications at 60 mm/sec +/-.8 mm/sec. You know that product which measures | |||||
| +/- .8 mm/sec from the mean costs the company an extra $ | 31.72 | per unit. You also know that it will cost you $ | 9.52 | per unit to adjust | |
| a product to 60 mm/sec. You also know that your process is a 3 sigma process and the mean is | 0.39 | SD less | than | ||
| the target. The firm accepts Taguchi’s loss function as a viable means of modeling costs. How much is your | |||||
| process 1) currently costing you if you do nothing, 2) if you fix those that make sense to fix? Would you spend | 7.6893079093 | million | |||
| dollars to create a centered process with a Cp ranging from 1.5 to 2? If you did have such a process, would you adjust or not adjust | |||||
| (support using Taguchi’s cost function)? Production is | 100340 | units per month (accrue monthly), costs $5000 per month to | |||
| inspect each unit, productive life cycle of the product is projected to be | 4.516980932 | years, and the discount rate is expected to range from | |||
| 9% to 15%APR. Support your answer both quantitatively (95% CL, n = 50) and qualitatively (six stake holder consideration). | |||||
| Problem 4 (3 points)) What decision do you make relative to control charts when you know the costs of Type I and Type II errors? | |||||
| Problem 5 (2 points) What is the purpose of step 18 in the process of creating a QCP? | |||||
| Problem 6, 38 points | takt time is | 2.3447 | minutes, work 24/7/365 | 30.4166666667 | days in a month |
| Specifications are .5″. +/- .001 inches, it costs | 386.16 | dollars when product is below the lower tolerance and | 58.62 | dollars | |
| labor and $100 per .001 inch to bring those above the upper tolerance to 1 SD below tolerance. The SD of the process is | 0.0002812013 | . | |||
| I can also change the system to a 5 to 6 sigma process for | 2.3446539546 | million dollars. The organization accrues monthly, has a discount | |||
| rate that varies between 10 and 15% APR, looks only 3 years into the future on any project, is spending an additional $7000/month to inspect the | |||||
| product, if put in the new system will spend only $2000 to control the process, currently the machine is set to produce a mean that is on target. | |||||
| Is there a business rule you could change currently to save money with the system as is, and what should that rule be if there is one? Should | |||||
| you alter the system to reduce the SD, show your answer as a 95% confidence interval using a sample of 50. Do not forget to judge your decision | |||||
| from the perspectives of all stakeholders. |
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