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CORK INSTITUTE OF TECHNOLOGY
INSTITIÚID TEICNEOLAÍOCHTA CHORCAÍ
Semester 1 Examinations 2008/
Module Title: Quality Engineering
Module Code: MANU
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_Y
External Examiner(s): Mr. Murtagh Murphy, Dr. David Fitzpatrick Mr. Neil Kingston, Mr. Joe Phelan
Internal Examiner(s): Sally Bryan
Instructions: Answer THREE questions
Duration: 2 Hours
Sitting: Winter 2008
Requirements for this examination:
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.
Q. 1
a) State the four categories of quality costs and give one example of each. (4 marks) b) Why is it important to consider quality costs? (4 marks) c) Explain why TQM requires higher levels of employee/management involvement and committment. (7 marks) d) Briefly explain three different methods that a company can use to implement TQM. (9 marks) e) Describe the key elements of vendor rating. (9 marks)
Q. 2
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 specification 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)
DATA SHEET
Attribute Chart Formulas
Defectives (Binominal Distributio
p-chart (% Defectives)
n p = np (for fraction) p = npn × 100 (for %)
n LCL p p p
n UCL p p p
3 (^1 )
3 (^1 )
= −^ −
k n =Σ n
n p np Σ
SAMPLE SIZE VARIES
np-Chart (Defectives)
LCL np np p
UCL np np p
k np np
k = number of samples
SAMPLE SIZE FIXED
Defects (Poisson Distribution)
u-Chart (Average number of defects)
n u c
k n n
n
LCL u u
n
UCL u u
n u c
SAMPLE SIZE VARIES
c-Chart (Number of Defects)
LCL c c
UCL c c
k c c
k = number of samples
SAMPLE SIZE FIXED
