Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions

What is the control step in DMAIC?
What is a robust design in Taguchi's quality engineering?
What is ISO 9000?
What are the three main objectives of Total Quality Management?
What do the terms external customer and internal customer mean?
Manufacturing process variations can be divided into two types: (1) random and (2) assignable. Distinguish between these two types.
What is meant by the term process capability?
What is a control chart?
What are the two basic types of control charts?
What is a histogram?
A turning process is in statistical control and the output is normally distributed, producing parts with a mean diameter = 30.020 mm and a standard deviation = 0.040 mm. Determine the process capability.
A p chart is to be constructed. Six samples of 25 parts each have been collected, and the average number of defects per sample = 2.75. Determine the center, LCL and UCL for the p chart.
Ten samples of equal size are taken to prepare a p chart. The total number of parts in these ten samples was 900 and the total number of defects counted was 117. Determine the center, LCL and UCL for the p chart.
The yield of good chips during a certain step in silicon processing of integrated circuits averages 91%. The number of chips per wafer is 200. Determine the center, LCL, and UCL for the p chart that might be used for this process.
The upper and lower control limits for a p chart are: LCL = 0.10 and UCL = 0.24. Determine the sample size n that is used with this control chart.
The upper and lower control limits for a p chart are: LCL = 0 and UCL = 0.20. The center line of the p chart is at 0.10. Determine the sample size n that is compatible with this control chart.
Twelve cars were inspected after final assembly. The number of defects found ranged between 87 and 139 defect per car with an average of 116. Determine the center and upper and lower control limits for the c chart that might be used in this situation.
For each of the three control charts, identify whether or not there is evidence that the process depicted is out of control.
A garment manufacturer produces 22 different coat styles, and every year new coat styles are introduced and old styles are discarded. Whatever the style, the final inspection department checks each coat before it leaves the factory for nine features that are considered critical-to-quality (CTQ)
A producer of cell phones checks each phone prior to packaging, using seven critical-to-quality (CTQ) characteristics that are deemed important to customers. Last year, out of 205,438 phones produced by the company, a total of 578 phones had at least one defect, and the total number of defects
The inspection department in an automobile final assembly plant checks cars coming off the line against 85 features that are considered critical-to-quality characteristics for customer satisfaction. During a one-month period, a total of 16,578 cars were produced. For those cars, a total of 1,989
In previous problem 20.1, the design specification on the part is that the diameter = 30.000 ( 0.150 mm. (a) What proportion of parts fall outside the tolerance limits? (b) If the process is adjusted so that its mean diameter = 30.000 mm and the standard deviation remains the same, what proportion
A digital camera maker produces three different models: (1) base model, (2) zoom model, and (3) zoom model with extra memory. Data for the three models are shown in the table below. The three models have been on the market for one year, and the first year's sales are given in the table. Also given
A certain part dimension on a power garden tool is specified as 25.50 ( 0.30 mm. Company repair records indicate that if the (0.30 mm tolerance is exceeded, there is a 75% chance that the product will be returned for replacement. The cost associated with replacing the product, which includes not
The design specification on the resistance setting for an electronic component is 0.50 (0.02 ohm. If the component is scrapped, the company suffers a $200 cost. (a) What is the implied value of the constant k in the Taguchi quadratic loss function? (b) If the output of the process that sets the
The Taguchi quadratic loss function for a particular component in a piece of earth moving equipment is L(x) = 3500(x - N)2 , where x = the actual value of a critical dimension and N is the nominal value. If N = 150.00 mm, determine the value of the loss function for tolerances of (a) (0.20 mm
The Taguchi loss function for a certain component is given by L(x) = 8000(x - N)2, where x = the actual value of a dimension of critical importance and N is its nominal value. Company management has decided that the maximum loss that can be accepted is $10.00. (a) If the nominal dimension is 30.00
Two alternative manufacturing processes, A and B, can be used to produce a certain dimension on one of the parts in an assembled product. Both processes can produce parts with an average dimension at the desired nominal value. The tolerance on the dimension is ( 0.15 mm. The output of each process
Solve previous problem 20.25, except that the tolerance on the dimension is ( 0.30 mm rather than ( 0.15 mm. Problem 20.25 Two alternative manufacturing processes, A and B, can be used to produce a certain dimension on one of the parts in an assembled product. Both processes can produce parts with
Solve previous problem 20.25, except that the average value of the dimension produced by process B is 0.10 mm greater than the nominal value specified. The average value of the dimension produced by process A remains at the nominal value N. Problem 20.25 Two alternative manufacturing processes, A
Two different manufacturing processes, A and B, can be used to produce a certain component. The specification on the dimension of interest is 100.00 mm ( 0.20 mm. The output of process A follows the normal distribution, with ( = 100.00 mm and ( = 0.10 mm. The output of process B is a uniform
An automated tube bending operation produces parts with an included angle = 91.2(. The process is in statistical control and the values of included angle are normally distributed with a standard deviation = 0.55(. The design specification on the angle = 90.0( ( 2.0(. (a) Determine the process
A plastic extrusion process is in statistical control and the output is normally distributed. Extrudate is produced with a critical cross-sectional dimension = 28.6 mm and standard deviation = 0.53 mm. Determine the process capability.
In previous problem 20.4, the design specification on the part is that the critical cross-sectional dimension = 28.0 ( 2.0 mm. (a) What proportion of parts fall outside the tolerance limits? (b) If the process were adjusted so that its mean diameter = 28.0 mm and the standard deviation remained the
Seven samples of 5 parts each have been collected from an extrusion process which is in statistical control, and the diameter of the extrudate has been measured for each part.
Ten samples of size n = 8 have been collected from a process in statistical control, and the dimension of interest has been measured for each part.
(b) Lower and upper control limits for the R chart.
(b) Lower and upper control limits for the R chart.
What is inspection?
What is the difference between off-line inspection and on-line inspection?
Under what circumstances is process monitoring a suitable alternative to actual inspection of the quality characteristic of the part or product?
What is the difference between distributed inspection and final inspection in quality control?
Briefly define the two basic types of inspection.
What are the four steps in a typical inspection procedure?
What are the Type I and Type II errors that can occur in inspection?
What is quality control testing as distinguished from inspection?
What are the Type I and Type II statistical errors that can occur in acceptance sampling?
Describe what an operating characteristic curve is in acceptance sampling.
What are the two problems associated with 100% manual inspection?
What are the three ways in which an inspection procedure can be automated?
(a) An inspector reported a total of 18 defects out of a total batch size of 250 parts. On closer examination, it was determined that 5 of these reported defects were in fact good pieces, while a total of 9 defective units were undetected by the inspector. What is the inspector's accuracy in this
A certain industrial process can be depicted by the diagram below. Operation 1 is a disassembly process in which each unit of raw material is separated into one unit each of parts A and B. These parts are then processed separately in operations 2 and 3, respectively, which have scrap rates of q2 =
A certain component is produced in three sequential operations. Operation 1 produces defects at a rate q1 = 5%. Operation 2 produces defects at a rate q2 = 8%. Operation 3 produces defects at a rate q3 = 10%. Operations 2 and 3 can be performed on units that are already defective. If 10,000
An industrial process can be depicted as in the diagram below. Two components are made, respectively, by operations 1 and 2, and then assembled together in operation 3. Scrap rates are as follows: q1 = 0.20, q2 = 0.10, and q3 = 0. Input quantities of raw components at operations 1 and 2 are 25,000
Two inspection alternatives are to be compared for a processing sequence consisting of 20 operations performed on a batch of 100 starting parts: (1) one final inspection and sortation operation following the last processing operation, and (2) distributed inspection with an inspection and sortation
In the preceding problem, instead of inspecting and sorting after every operation, the 20 operations will be divided into groups of five, with inspections after operations 5, 10, 15, and 20. Following the logic of Eq. (21.11), the cost of each inspection will be five times the cost of inspecting
A processing sequence consists of 10 operations, each of which is followed by an inspection and sortation operation to detect and remove defects generated in the processing operation. Defects in each process occur at a rate of q = 0.04. Each processing operation costs $1.00 per unit processed, and
This problem is intended to show the merits of a partially distributed inspection systems in which inspections are placed after processing steps that generate a high fraction defect rate. The processing sequence consists of eight operations with fraction defect rates for each operation as
A batch of 1000 parts has been produced and a decision is needed whether to 100% inspect the batch or not. Past history with this part suggests that the fraction defect rate is around 0.02. Inspection cost per part is $0.20. If the batch is passed on for subsequent processing, the damage cost for
Given the data from the preceding problem, sampling inspection is being considered as an alternative to 100% inspection. The sampling plan calls for a sample of 50 parts to be drawn at random from the batch. Based on the operating characteristic curve for this sampling plan, the probability of
For the preceding problem, develop a table of outcomes similar in format in the text. The entries in the table should represent the probabilities of the various possible outcomes in the inspection operation.
Develop a table of outcomes similar in format in the text. The entries will be the probabilities of the various possible outcomes in the inspection operation.
An inspector's accuracy has been assessed as follows: p1 = 0.94 and p2 = 0.80. The inspector is given the task of inspecting a batch of 200 parts and sorting out the defects from good units. If the actual defect rate in the batch is q = 0.04, determine (a) the expected number of Type I and (b) Type
An inspector must 100% inspects a production batch of 500 parts using a gagging method. If the actual fraction defect rate in the batch is q = 0.02, and the inspector's accuracy is given by p1 = 0.96 and p2 = 0.84, determine (a) The number of defects the inspector can be expected to report and
A batch of 10,000 raw work units is processed through 15 operations, each of which has a fraction defect rate of 0.03. How many defect-free units and how many defects are in the final batch?
A silicon wafer has a total of 400 integrated circuits (ICs) at the beginning of its fabrication sequence. A total of 80 operations are used to complete the integrated circuits, each of which inflicts damages on 1.5% of the ICs. The damages compound, meaning that an IC that is already damaged has
A batch of work parts is processed through a sequence of nine processing operations, which have fraction defect rates of 0.03, 0.05, 0.02, 0.04, 0.06, 0.01, 0.03, 0.04, and 0.07, respectively. A total of 5000 completed parts are produced by the sequence. What was the starting batch quantity?
A production line consists of six workstations, as shown in the accompanying figure. The six stations are as follows: (1) First manufacturing process, scrap rate is q1 = 0.10; (2) Inspection for first process, separates all defects from first process; (3) Second manufacturing process, scrap rate is
Name the four categories into which the methods of operating and controlling a CMM can be classified.
What does the term reverse engineering mean in the context of coordinate measuring machines?
The text lists seven characteristics of potential applications for which CMMs are most appropriate. Name four of the seven characteristics.
What are some of the arguments and objections to the use of inspection probes mounted in tool holders on machine tools?
What is the most common method used to measure surfaces of a part?
The operation of a machine vision system can be divided into three functions. Name and briefly describe them.
What is an optical comparator?
What is the difference between accuracy and precision in measurement? Define these two terms.
What is meant by the term contact inspection?
What are some of the advantages of noncontact inspection?
What is meant by the term coordinate metrology?
What are the two basic components of a coordinate measuring machine?
Two point locations corresponding to a certain length dimension have been measured by a coordinate measuring machine in the x-y plane. The coordinates of the first end are (12.511, 2.273), and the coordinates of the opposite end are (4.172, 1.985), where the units are in inches. The coordinates
A solid-state camera has a 256 x 256 pixel matrix. The analogtodigital converter takes 0.20 microseconds (0.20 x 10-6 sec) to convert the analog charge signal for each pixel into the corresponding digital signal. If there is no time loss in switching between pixels, determine the following: (a)
The pixel count of a solid-state camera is 500 x 582. Each pixel is converted from an analog voltage signal to the corresponding digital signal by an analogtodigital converter. The conversion process takes 0.08 microseconds (0.08 x 10-6 sec) to complete. Given this time, how long will it take to
A high-resolution solid state camera is to have a 1035 x 1320 pixel matrix. An image processing rate of 30 times per second must be achieved, or 0.0333 sec per frame. To allow for time lost in other data processing per frame, the total ADC time per frame must be 80% of the 0.0333 sec, or 0.0267
A solid-state camera system has 512 x 512 picture elements. All pixels are converted sequentially by an ADC and read into the frame buffer for processing. The machine vision system will operate at the rate of 30 frames per second. However, in order to allow time for data processing of the contents
A scanning laser device, similar to the one shown in Figure 22.12, is to be used to measure the diameter of shafts that are ground in a center less grinding operation. The part has a diameter of 0.475 inch with a tolerance of (0.002 inch. The four-sided mirror of the scanning laser beam device
Triangulation computations are to be used to determine the distance of parts moving on a conveyor. The setup of the optical measuring apparatus is as illustrated in the text. The angle between the beam and the surface of the part is 25(. Suppose for one given part passing on the conveyor, the
The coordinates at the two ends of a certain length dimension have been measured by a CMM. The coordinates of the first end are (120.5, 50.2, 20.2), and the coordinates of the opposite end are (23.1, 11.9, 20.3), where the units are in mm. The given coordinates have been corrected for probe radius.
Three point locations on the surface of a drilled hole have been measured by a CMM in the x-y axes. The three coordinates are: (16.42, 17.17), (20.20, 11.85), and (24.08, 16.54), where the units are mm. These coordinates have been corrected for probe radius. Determine (a) the coordinates of the
Three point locations on the surface of a cylinder have been measured by a coordinate measuring machine. The cylinder is positioned so that its axis is perpendicular to the x-y plane. The three coordinates in the x-y axes are: (5.242, 0.124), (0.325, 4.811), and (-4.073, -0.544), where the units
Two points on a line have been measured by a CMM in the x-y plane. The point locations have the following coordinates: (12.257, 2.550) and (3.341, -10.294), where the units are inches and the coordinates have been corrected for probe radius. Find the equation for the line.
Two points on a line are measured by a CMM in the x-y plane. The points have the following coordinates: (100.24, 20.57) and (50.44, 60.46), where the units are mm. The given coordinates have been corrected for probe radius. Determine the equation for the line.
The coordinates of the intersection of two lines are to be determined using a CMM to define the equations for the two lines. The two lines are the edges of a machined part, and the intersection represents the corner where the two edges meet. Both lines lie in the x-y plane. Measurements are in
Two of the edges of a rectangular part are represented by two lines in the x-y plane on a CMM worktable, as illustrated in. It is desired to mathematically redefine the coordinate system so that the two edges are used as the x- and y-axes, rather than the regular x-y axes of the CMM. To define the
Three point locations on the flat surface of a part have been measured by a CMM. The three point locations are (225.21, 150.23, 40.17), (14.24, 140.92, 38.29), and (12.56, 22.75, 38.02), where the units are mm. The coordinates have been corrected for probe radius. (a) Determine the equation for the
What are manufacturing support systems?
What is the difference between CAD/CAM and CIM?
What is quality function deployment?
What are the six phases of the general design process?
What is computer-aided design?

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Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions

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