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Quality Improvement 9th Edition Dale Besterfield - Solutions

5. When the tensile strength of a plastic part is 120 lb/in.2, there is an average loss of $34.00 due to breakage.Determine the average loss for sample tests of 130, 132, 130, 132, and 131.Hint: Use larger-the-better formula.
6. A new process is proposed for the manufacture of steel shafts, as given in the example problem on page 566 .Data are 6.38, 6.40, 6.41, 6.38, 6.39, 6.36, and 6.37.a. What is the expected loss?b. Is the new process better than the process of the example?c. What future improvements might be
17. The results of a nominal-the-best experimental design are as follows:a. Determine the response table, response graph, and strong effects.b. Analyze your results in terms of adjustment factors and variation factors. A B C TC 1 2 3 N1 N2 y S/N 1 1 1 23 2 3 4 122 1 2 12 1.75 1.84 1.80 29.01 1.34
18. The results for a smaller-the-better saturated experimental design using an OA16 with 15 factors where the factors A, B,c, O are located in columns 1, 2,c, 15, respectively, are as follows:a. Determine the response table, response graph, strong effects, and prediction for the average and the
19. The results of a larger-the-better experimental design with an outer array for noise are as follows:a. Determine the response table, response graph, strong effects, and prediction for the S/N ratio.b. What value for the confirmation run would you consider satisfactory? TC A B C D NI N2
20. The results of a smaller-the-better experimental design are as follows:a. Determine the response table, response graph, and strong effects.b. Explain the results. B A AB C UX AC D TC 4 5 Ho 222 123 + in 678 1 2 3 4 5 6 7 S/N 1 1 1 1 1 1 1 1 2 2 2 12 12 32.1 33.6 1 2 2 1 1 2 2 32.8 1 2 2 2 2 1 1
21. Determine the percent contributions of Exercise 16.
22. Determine the percent contributions of Exercise 20.
23. The confirmation run for the experimental design of an electronic device gave the following percent contributions for unpooled factors from an OA12 design. Also given is the upgrade effect and the upgrade cost.If the total SS is 1301.2 and k = 0.05, determine the net gain per unit from
24. A four-factor experiment gives the following percent contributions for the confirmation run: A (43%), B (9%), C (28%), D (13%), and residual (7%). If the variance is currently 225 and the desired value is 100, determine two possible reduction schemes.
16. The results for a larger-the-better experimental design that was run in random order with seven factors are as follows:a. Determine the response table, response graph, strong effects, and prediction for the average and the S/N ratio.b. If the confirmation run is 27.82, what can you say about
15. The yield on a new chemical process for five days is 61, 63, 58, 57, and 60 and the old process had recent yields of 54, 56, 52, 56, 53, 51, 54, 53, and 52. Is the new process better? If so, how much better?
7. Given three two-level factors and three suspected twofactor interactions, determine the degrees of freedom and the OA.
8. If a three-factor interaction was also suspected in Exercise 7, what are the degrees of freedom and the OA? What type of OA is this design?
9. What are the degrees of freedom and OA if the factors in Exercise 7 are three-level? Why does a three-level design require so much more design space?
10. An experimental design has five two-level factors ( A, B, C, D, E ), where only main effects are possible for factor C and there are no suspected AB and three-factor or higher interactions. Using a linear graph, assign the factors and their interactions to the columns of the OA.
11. Using a linear graph, assign the factors and their interactions to the columns of the OA determined in Exercise 7.
12. Using a linear graph, assign the factors and their interactions to the columns of the OA determined in Exercise 9.
13. A new process has been developed and the temperature results are 21C for the average and 0.8C for the sample standard deviation (n = 5).a. What is the S/N ratio for nominal-the-best?b. How much improvement has occurred? Compare to the nominal-the-best Example Problem 14-5 answer of 20.41
14. Suppose the results of the new process for the bread stuffing example problem are 125, 132, 138, 137, 128, and 131. What conclusions can be drawn?
25. Design and conduct a Taguchi experiment fora. growth of a house plant;b. flight of a paper airplane;c. baking brownies, chocolate-chip cookies, and so forth;d. making coffee, popcorn, etc.;e. any organization listed in Chapter 1 , Exercise 5.
1. Using the judicial system as an example, explain Type I and II errors in hypothesis testing.
1. A system has 4 components, A, B, C, and D, with reliability values of 0.98, 0.89, 0.94, and 0.95, respectively.If the components are in series, what is the system reliability?
12. Assume a constant failure rate and determine the mean life for Exercises 9, 10, and 11.
13. Determine the failure rate for a 150-h test of 9 items, where 3 items failed without replacement at 5, 76, and 135 h. What is the mean life for a constant failure rate?
14. If the mean life for a constant failure rate is 52 h, what is the failure rate?
16. Using normal distribution, determine the reliability at 6000 cycles of a switch with a mean life of 5500 cycles and a standard deviation of 165 cycles.
17. Determine the reliability at t = 80 h for the Example Problem 11-10, where u = 125 and there is a constant failure rate. What is the reliability at t = 125 h ? At t = 160 h ?
18. Determine the reliability at t = 3500 cycles for Example Problem 11-10, where the mean life of a constant failure rate is 3704 cycles. What is the reliability at t = 3650 cycles? At 3900 cycles?
19. Using the Weibull distribution for Exercise 16 rather than the normal distribution, determine the reliability when b = 3.5 .
20. The failure pattern of an automotive engine water pump fits the Weibull distribution with b = 0.7. If the mean life during the debugging phase is 150 h, what is the reliability at 50 h?
11. Fifty parts are tested for 500 cycles each. When a part fails, it is replaced by another one. At the end of the test, 5 parts had failed. What is the failure rate?
10. Twenty-five parts are tested for 15 h. At the end of the test, 3 parts had failed at 2, 5, and 6 h. What is the failure rate?
2. A flashlight has 4 components: 2 batteries with reliability of 0.998, a light bulb with reliability of 0.999, and a switch with reliability of 0.997. Determine the reliability of this series system.
3. Christmas tree light bulbs used to be manufactured in series—if one bulb went out, they all did. What would be the reliability of this system if each bulb had a reliability of 0.999 and there were 20 bulbs in the system?
4. What is the reliability of the system below? 0.936 0.971
5. If component B of Exercise 1 is changed to 3 parallel components and each has the same reliability, what is the system reliability now?
6. What is the reliability of the system below, where the reliabilities of components A, B, C, and D are 0.975, 0.985, 0.988, and 0.993, respectively? A C B D
7. Using the same reliabilities as in Exercise 6, what is the reliability of the system below? A B
8. A system is composed of 5 components in series, and each has a reliability of 0.96. If the system can be changed to 3 components in series, what is the change in the reliability?
9. Determine the failure rate for 5 items that are tested to failure. Test data in hours are 184, 96, 105, 181, and 203.
21. Construct the OC curve for a sampling plan specified as n = 24, T = 149, c = 7, and r = 8.
22. Construct the OC curve for a sampling plan specified as n = 10, T = 236, c = 4, and r = 5.
23. Determine the time-terminated, with-replacement, mean-life sampling plan where the producer’s risk of rejecting lots with mean life of 800 h is 0.05 and the consumer’s risk of accepting lots with mean life u1 = 220 is 0.10. The sample size is 30.
4. Using a team of three or more people, prepare an interrelationship digraph for thea. computer networking of nine locations in the organization’s facility;b. implementation of a recognition and reward system;c. performance improvement of the accounting department or any other work group.
5. Develop a tree diagram, using a team of three or more people, fora. the customer requirements for a product or service;b. planning a charity walkathon.
6. The church council is planning the activities for a successful carnival. Using a team of three or more people, design a tree diagram to determine detailed assignments.
7. Develop a matrix diagram to design an organizationwide training or employee involvement program. Use a team of three or more people.
8. Using a team of three or more people, construct a matrix diagram toa. determine customer requirements for a new product or service;b. allocate team assignments to implement a project such as new student week;c. compare teacher characteristics with potential student performance.
9. Develop a prioritization matrix, using the tree diagram developed in Exercise 6.
10. Construct a PDPC fora. a charity walkathon (see Exercise 5);b. the church carnival of Exercise 6;c. the matrix diagram developed in Exercise 7.
11. Using a team of three or more people, construct an activity network diagram fora. constructing a cardboard boat;b. an implementation schedule for a university event such as graduation;c. developing a new instructional laboratory.
3. Prepare an affinity diagram, using a team of three or more people, to plana. an improvement in the cafeteria;b. a spring-break vacation;c. a field trip to a local organization.
2. Use the forced field analysis toa. lose weight;b. improve your GPA;c. increase your athletic ability in some sport.
24. Determine the time-terminated, with-replacement sampling plan that has the following specifications:T = 160, u1 = 400, b = 0.10, u0 = 800, and a = 0.05.
25. Determine the time-terminated, with-replacement sampling plan where the producer’s risk of rejecting lots with mean life u0 = 900 h is 0.05, the rejection number is 3, and the sample size is 9.
26. Find a replacement life-test sampling plan of 300 h that will accept a lot with mean life of 3000 h 95% of the time but will reject a lot with mean life of 1000 h 90%of the time.
27. If the probability of accepting a lot with a mean life of 1100 cycles is 0.95 and the probability of not accepting a lot with mean life of 625 cycles is 0.90, what is the sampling plan for a sample size of 60?
28. Find a life-test, time-terminated sampling plan with replacement that will accept a lot with a mean life of 900 h with probability of 0.95 (a = 0.05). The test is to be stopped after the occurrence of the second failure, and 12 units of product are to be placed on test.
29. Using EXCEL, design a template for the construction of an OC curve and test it by solving Exercise 21.
30. Using the EXCEL program file for the Weibull distribution, determine b and u for the ordered data set 20, 32, 40, 46, 54, 62, 73, 85, 89, 99, 102, 118, 140, 151.
1. Determine why you did poorly on a recent examination by using the why, why tool.
12. With a team of three or more people, select a problem or situation and use the seven management and planning tools to implement an action plan. If one of the tools doesn’t fit, justify its exclusion.
17. An electrician testing the incoming line voltage for a residential house obtains 5 readings: 115, 113, 121, 115, 116. What is the average?
28. Frequency tests of a brass rod 145 cm long give values of 1200, 1190, 1205, 1185, and 1200 vibrations per second.What is the sample standard deviation?
29. Four readings of the thickness of the paper in this textbook are 0.076 mm, 0.082 mm, 0.073 mm, and 0.077 mm. Determine the sample standard deviation.
30. The frequency distribution given here shows the percent of organic sulfur in Illinois No. 5 coal. Determine the sample standard deviation. Cell Midpoint (%) Frequency (Number of Samples) 0.5 0.8 1.1 1.4 -629 1 16 12 10 1.7 12 2.0 18 2.3 16 2.6 3
31. Determine the sample standard deviation for the following:a. The data of Exercise 9b. The data of Exercise 19
32. Determine the average and sample standard deviation for the frequency distribution of the number of inspections per day as follows:Cell Midpoint Frequency 1000 6 1300 13 1600 22 1900 17 2200 11 2500 8
33. Using the data of Exercise 19, construct:a. A polygonb. An ogive
34. Using the data of Exercise 20, construct:a. A polygonb. An ogive
35. Using the data of Exercise 30, construct:a. A polygonb. An ogive
27. Determine the range for each set of numbers.a. 16, 25, 18, 17, 16, 21, 14b. 45, 39, 42, 42, 43c. The data in Exercise 6d. The data in Exercise 7
26. Determine the modal cell of the data in:a. Exercise 6b. Exercise 7c. Exercise 8d. Exercise 9e. Exercise 19f. Exercise 20
18. An employee makes 8 trips to load a trailer. If the trip distances in meters are 25.6, 24.8, 22.6, 21.3, 19.6, 18.5, 16.2, and 15.5, what is the average?
19. Tests of noise ratings at prescribed locations throughout a large stamping mill are given in the following frequency distribution. Noise is measured in decibels.Determine the average. Cell Midpoint 148 139 130 121 112 Frequency 23 8 11 27 35 103 94 43 85 33 76 20 67 12 58 6 49 4 40 2
20. The weight of 65 castings in kilograms is distributed as follows:Determine the average. Cell Midpoint Frequency 6 3.5 3.8 4.1 4.4 4.7 5.0 9 18 14 13 5
21. Destructive tests on the life of an electronic component were conducted on 2 different occasions. On the first occasion, 3 tests had a mean of 3320 h; on the second occasion, 2 tests had a mean of 3180 h. What is the weighted average?
22. The average height of 24 students in Section 1 of a course in quality control is 1.75 m; the average height of 18 students in Section 2 of quality control is 1.79 m;and the average height of 29 students in Section 3 of quality control is 1.68 m. What is the average height of the students in the
23. Determine the median of the following numbers.a. 22, 11, 15, 8, 18b. 35, 28, 33, 38, 43, 36
24. Determine the median for the following:a. The frequency distribution of Exercise 8b. The frequency distribution of Exercise 9c. The frequency distribution of Exercise 19d. The frequency distribution of Exercise 20e. The frequency distribution of Exercise 30f. The frequency distribution of
25. Given the following series of numbers, determine the mode.a. 50, 45, 55, 55, 45, 50, 55, 45, 55b. 89, 87, 88, 83, 86, 82, 84c. 11, 17, 14, 12, 12, 14, 14, 15, 17, 17
36. Using the data of Exercise 32, construct:a. A polygonb. An ogive
37. Using the data of Exercise 19, construct:a. A histogramb. A relative frequency histogramc. A cumulative frequency histogramd. A relative cumulative frequency histogram
38. Using the data of Exercise 20, construct:a. A histogramb. A relative frequency histogramc. A cumulative frequency histogramd. A relative cumulative frequency histogram
49. Using the information of Exercise 41, what is your judgment concerning the normality of the distribution in each of the following?a. Exercise 6b. Exercise 7c. Exercise 8d. Exercise 9e. Exercise 20f. Exercise 32
Using normal probability paper, determine (judgment)the normality of the distribution of the following.a. Second column of Table 5-4b. First three columns of Exercise 7c. Second column of Exercise 8
By means of a scatter diagram, determine if a relationship exists between product temperatures and percent foam for a soft drink. Data are as follows: Product Temperature Foam Product Temperature Foam Day (F) (%) Day (F) (%) 12 36 38 3 37 522 15 11 44 32 19 12 42 33 21 13 38 20 4 44 30 14 41 27 5
By means of a scatter diagram, determine whether there is a relationship between hours of machine use and millimeters off the target. Data for 20 ( x , y ) pairs with hours of machine use as the x variable are (30, 1.10),(31, 1.21), (32, 1.00), (33, 1.21), (34, 1.25), (35, 1.23),(36, 1.24), (37,
53. Data on gas pressure (kg/cm 2 ) and its volume (liters) are as follows: (0.5, 1.62), (1.5, 0.75), (2.0, 0.62), (3.0, 0.46),(2.5, 0.52), (1.0, 1.00), (0.8, 1.35), (1.2, 0.89), (2.8, 0.48),(3.2, 0.43), (1.8, 0.71), and (0.3, 1.80). Construct a scatter diagram. Determine the coefficient of
54. The following data (tensile strength, hardness) are for tensile strength (100 psi) and hardness (Rockwell E) of die-cast aluminum. Construct a scatter diagram and determine the relationship: (293, 53), (349, 70), (368, 40), (301, 55), (340, 78), (308, 64), (354, 71), (313, 53), (322, 82), (334,
Data on the amount of water applied in inches and the yield of alfalfa in tons per acre are as follows:Water 12 18 24 30 36 42 48 60 Yield 5.3 5.7 6.3 7.2 8.2 8.7 8.4 8.2 Prepare a scatter diagram and analyze the results. What is the coefficient of correlation?
Using the EXCEL software, determine the descriptive statistics and histogram using the data of the following:a. Exercise 6b. Exercise 7c. Exercise 8d. Exercise 9e. Exercise 19f. Exercise 20 g. Exercise 30 h. Exercise 32
48. In the precision grinding of a complicated part, it is more economical to rework the part than to scrap it.Therefore, it is decided to establish the rework percentage at 12.5%. Assuming normal distribution of the data, a standard deviation of 0.01 mm, and an upper specification limit of 25.38
47. A cold cereal manufacturer wants 1.5% of the product to be below the weight specification of 0.567 kg (1.25 lb). If the data are normally distributed and the standard deviation of the cereal filling machine is 0.018 kg, what mean weight is required?
39. Using the data of Exercise 30, construct:a. A histogramb. A relative frequency histogramc. A cumulative frequency histogramd. A relative cumulative frequency histogram
40. Using the data of Exercise 32, construct:a. A histogramb. A relative frequency histogramc. A cumulative frequency histogramd. A relative cumulative frequency histogram
41. Determine the skewness, kurtosis, and coefficient of variation of:a. Exercise 6b. Exercise 7c. Exercise 8d. Exercise 9e. Exercise 20f. Exercise 32
42. If the maximum allowable noise is 134.5 decibel (db), what percent of the data of Exercise 19 is above that value?
43. Evaluate the histogram of Exercise 20, where the specifications are 4.25, 6, and 0.60 kg.

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