The following table lists all costs of quality incurred by Sams Surf Shop last year. What was Sams appraisal cost for quality last year? Annual inspection costs $ 155,000 Annual cost of scrap materials 286,000 Annual rework cost 34,679 Annual cost of quality training 456,000 Annual warranty cost 1,546,000 Annual testing cost 543,000 10. A manufacturing company has been inspecting units of output from a process. Each product inspected is evaluated on fi ve criteria. If the unit does not meet standards for the criteria it counts as a defect for the unit. Each unit could have as few as zero defects, and as many as fi ve. After inspecting 2,000 units, they discovered 33 defects. What is the DPMO measure for this process? ( Chapter 12 Question 7, and 10 ) Single Excel File done like this 12.7, 12.10 (above) ( Chapter 13 6, 7, 8, 9 ) Single Excel file only! 13.6, 13.7, 13.8, 13.9 (Below) 6. C-Spec, Inc., is attempting to determine whether an existing machine is capable of milling an engine part that has a key specifi cation of 4 6 .003 inches. 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 .002 inch. a. Calculate the Cpk for this machine. b. Should C-Spec use this machine to produce this part? Why? LO132 7. Ten samples of 15 parts each were taken from an ongoing process to establish a p-chart for control. The samples and the number of defectives in each are shown in the following table: Sample n Number of Defective Items in the Sample Sample n Number of Defective Items in the Sample 1 2 3 4 5 15 15 15 15 15 3 1 0 0 0 6 7 8 9 10 15 15 15 15 15 2 0 3 1 0 a. Develop a p-chart for 95 percent confi dence (1.96 standard deviation). b. Based on the plotted data points, what comments can you make? 340 section 2 MANUFACTURING AND SERVICE PROCESSES 8. A shirt manufacturer buys cloth by the 100-yard roll from a supplier. For setting up a control chart to manage the irregularities (e.g., loose threads and tears), the following data were collected from a sample provided by the supplier. Sample 1 2 3 4 5 6 7 8 9 1 0 Irregularities 3 5 2 6 5 4 6 3 4 5 a. Using these data, set up a c-chart with z 5 2. b. Suppose the next fi ve rolls from the supplier had three, two, fi ve, three, and seven irregularities. Is the supplier process under control? 9. Resistors for electronic circuits are manufactured on a high-speed automated machine. The machine is set up to produce a large run of resistors of 1,000 ohms each. To set up the machine and to create a control chart to be used throughout the run, 15 samples were taken with four resistors in each sample. The complete list of samples and their measured values are as follows: Sample Number Readings (in ohms) 1 2 3 4 5 6 7 8 9 10 1010 995 990 1015 1013 994 989 1001 1006 992 991 996 1003 1020 1019 1001 992 986 989 1007 985 1009 1015 1009 1005 994 982 996 1005 1006 986 994 1008 998 993 1005 1020 996 1007 979 11 12 13 14 15 996 1019 981 999 1013 1006 996 991 993 1002 997 991 989 988 1005 989 1011 1003 984 992 Develop an __ X - chart and an R-chart and plot the values. From the charts, what comments can you make about the process? (Use three-sigma control limits as in Exhibit 13.7.) 10. You are the newly appointed assistant administrator at a local hospital, and your fi rst project is to investigate the quality of the patient meals put out by the food-service department. You conducted a 10-day survey by submitting a simple questionnaire to the 400 patients with each meal, asking that they simply check off that the meal was either satisfactory or unsatisfactory. For simplicity in this problem, assume that the response was 1,000 returned questionnaires from the 1,200 meals each day. The results are as follows: Number of Unsatisfactory Meals Sample