Suggest improvements that you feel could be made to Toyota's quality program. Also, what might Toyota do to improve its image to the consumer relative to quality?
a. If the specification is such that no washer should be greater than 2.4 millimeters, assuming that the thicknesses are distributed normally, what fraction of the output is expected to be greater than this thickness?
b. What if there is an upper and lower specification, where the upper thickness limit is 2.4 and the lower thickness limit 1.4, what fraction of the output is expected to be out of tolerance?
c. What is the Cpk for the process?
d. What would be the Cpk for the process if it were centered (assume the process standard deviation is the same)?
e. What percentage of output would be expected to be out of tolerance if the process were centered?
f. If the process could be improved so that the standard deviation was only about .10 millimeters, what would be the best that could be expected with the processes relative to fraction defective?
g. Setup X-bar and Range control charts for the current process. Assume the operators will take samples of 10 washers at a time.
h. Plot the data on your control charts. Does the current process appear to be in control?