Acceptance Sampling

Q1
1. Specific Motors Corp. has a new supplier for spark plugs and is
concerned about the incoming quality. They purchase spark plugs
in lots of 10,000 at a time and want to use Z 1.4 to determine an
acceptance sampling plan. Corporate officers have agreed on an
AQL value of 1.5% defectives and the use of general inspection
level II.
a. Determine the acceptance sampling plan you would recommend
using Standard Tables as a guideline.
b. Sketch the operating characteristic curve.
c. What is the value for the RQL (LQ or LTPD) for this sampling plan.
(assume = 0.10)
d. If the incoming quality is actually 3.5% defective, what is the
probability that your acceptance sampling plan accepts the lot [use
your OC curve in part b above to answer?
e. After a lot was accepted, many Specific Motors cars appeared to not
run very good and it was determined that the cause was defective
spark plugs. After an extensive study, it was determined that the
actual percent defective was in fact 3.5% defective (much larger
that the AQL of 1.5% defective). In order to protect yourself from
taking the risk of accepting this level of quality in the future, what
sampling plan would you suggest they switch to and why?
Q2
Sampling Tables MIL-STD/105D is an acceptance sampling scheme.
Explain the reasoning behind the switching rules associated with normal,
tightened, and reduced inspection. Use your own words. Do not copy any
documented explanations.

Q3
A shipment of 2,000 portable battery units for microcomputers is about to
be inspected by a Malaysian importer. The Korean manufacturer and the
importer have set up a sampling plan in which the _ risk is limited to 5% at
an acceptable quality level (AQL) of 2% defective, and the _ risk is set to
10% at Lot Tolerance Percent Defective (LTPD) = 7% defective. We want to
construct the OC curve for the plan of n = 120 sample size and an
acceptance level of c 3 defectives. Both firms want to know if this plan
will satisfy their quality and risk requirements.
N.B (varying the percent defectives (p) from .01 (1%) to .08 (8%) )
Q4

The percent defective from an incoming lot in Problem Q3 is 3%. An OC

curve showed the probability of acceptance to be .515. Given a lot size of
2,000 and a sample of 120, what is the average outgoing quality in
percent defective?

Q5
To illustrate the AOQ relationship, let us use the data we developed for the
OC curve in Problem Q3. The lot size in that case was N = 2,000 and the
sample size was n = 120. Assume that any defective batteries found
during inspection are replaced by good ones. Then using the formula for
AOQ given before and the probabilities of acceptance from Problem Q3,
can develop the AOQ curve.
Control Charts
1. The Perfect Circle Company manufactures bushings. Once each hour a sample of 125
finished bushings is drawn from the output; each bushing is examined by a technician.
Those which fail are classified as defective; the rest are satisfactory. Here are data on ten
consecutive samples taken in one week:
Sample no.
1
2
3
4
5
6
7
8
9
10
Defective
15
13
16
11
13
14
20
25
30
45
a. What type of control chart should be used here?
b. What is the centerline of the chart?
c. What is the lower control limit (LCL)? The upper control I?
d. What statistic should be plotted on the control chart for?
e. Draw the control chart on a piece of graph paper.
f. Is this system under control?
g. What should the quality control engineer do?
2. Use the data in Problem #1 in this problem. Assume that an assignable cause has been
found for Sample #10 and has been corrected.
a. What is the value of the centerline of the revised control chart?
b. What is the lower control limit of the revised chart?
c. What is the upper control limit of the revised chart?
d. Compare the revised control chart to the original control chart.
3. The Take-Charge Company produces batteries. From time to time a random sample of
six batteries is selected from the output and the voltage of each battery is measured, to be
sure that the system is under control. Here are statistics on 16 such samples.
Sample
Mean
Range
Sample
Mean
Range
1
4.99
0.41
9
5.01
0.49
2
4.87
0.57
10
5.19
0.56
3
4.85
0.59
11
5.40
0.44
4
5.26
0.74
12
5.15
0.63
5
5.09
0.74
13
5.00
0.35
6
5.02
0.21
14
4.89
0.45
7
5.13
0.56
15
4.99
0.54
8
5.09
0.92
16
5.05
0.33
a. What type of control chart should be used here? Why?
b. What is the centerline of the chart?

c. What is the lower control limit? The upper control limit?

d. What statistic should be plotted on the control chart for each sample?
e. Draw the control chart on a piece of graph paper.
f. Is this system under control?
g. What should the quality control engineer do?
4. Use the data in Problem 3 to draw an R chart.
a. What is the lower control limit? The upper control limit?
b. What statistic should be plotted on the control chart for each sample?
c. Draw the control chart on a piece of graph paper.
d. Is this system under control?
e. What should the quality control engineer do?
5. Assume that an assignable cause has been found and corrected for sample # 11 in
Problem 3.
a. What is the value of the centerline of the revised control chart?
b. What is the lower control limit of the revised chart? The upper control Limit?
c. Compare the revised control chart to the original control chart.