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CORK INSTITUTE OF TECHNOLOGY
INSTITIÚID TEICNEOLAÍOCHTA CHORCAÍ
Autumn 2010/
School: Mechanical & Process Engineering
Programme Title: Bachelor of Engineering (Hons) in Biomedical Engineering Bachelor of Science (Hons) in Process Plant Technology Bachelor of Science (Hons) in Advanced Manufacturing Technology
Programme Code: EBIOM_8_Y3, EPPTE_8_Y4, EAMTE_8_Y4,
Module Title: Quality Engineering
Module Code: MANU
External Examiner(s): Mr. P. Ryan, Mr. G. Reilly Internal Examiner(s): Sally Bryan
Instructions: Answer THREE questions
Duration: 2 Hours
Sitting: Autumn 2011
Requirements for this examination: None
Note to Candidates: Please check the Programme Title and the Module Title to ensure that you are attempting the correct examination. If in doubt please contact an Invigilator.
Q1.
a) Give four situations in which Acceptance Sampling may be appropriate method in a quality management system. (8 marks) b) Interpret the ASN (average sample number) curve shown in figure Q1. (9 marks) c) Obtain a single sampling plan using ANSI/ASQC Z1.4 tables. The lot size submitted for inspection is 2000, and it is agreed that the AQL should be 1.0%. The normal inspection level will be adopted. (12 marks) d) How would the plan in part c) change if you were to find 2 out of 5 consecutive lots rejected? (4 marks)
Figure Q1 – ASN Curve Q2. a) Compare and contrast common and special causes of variation. (8 marks) b) A critcal dimension of a product is measured as part of an inspection plan. The dimension is approximated by the normal distribution with a mean of 215mm and a standard deviation of 1mm. If the specifaication limits are 214 and 217mm what percentage of products are acceptable to the customer? (10 marks) c) C-Spec Inc., is attempting to determine whether an existing machine is capable of milling an engine part that has a key specification of 4±0.003inches. after a trial run on this machine, C-Spec has determined that the machine has a sample mean of 4.001 inches with a standard deviation of 0.002 inch. i. Briefly discuss why you would consider doing a capability study on this machine. (4 marks) ii. Calculate the capability indices Cp and Cpk (6 marks) iii. Should the machine be used? Why? (5 marks)
Q4.
a) Stakeholder analysis is undertaken by the project leader of a Six Sigma project in the define phase. What does stakeholder analysis identify and why might it be useful? (6 marks) b) Which of the " Seven Basic Quality Tools " would be most useful in the following scenarios? Explain the reasoning behind your answer. (15 marks) i. Streamlining a manufacturing process. ii. Checking if a machine had deteriorated since its last calibration. iii. Establishing if there is a connection between air temperature and product quality. c) Answer the following questions in relation to mistake proofing devices (Poka Yoke) i. List four such devices (4 marks) ii. Differentiate beteen detection and prevention type devices (4 marks) iii. State which phase of a Six Sigma project they would be most likely to be used. (4 marks)
