ent.uthm.edu

8/13/2019 Ent.uthm.Edu

1/7

UNIVERSITI TUN HUSSEIN ONNMALAYSIA

FINAL EXAMINATIONSEMESTER IISESSION 2009/2010

S U B J E C T N A M E

S U B J E C T C O D EC O U R S EE X A M I N A T I O N D A T ED U R A T I O NI N S T R U C T I O N

T O T A L Q U A L I T YM A N A G E M E N TB P B 2 0 8 32 B P A / 2 B P BA P R I L / M A Y 2 0 1 02 H O U R S 3 0 M I N U T E SP A R T AA N S W E R A L L Q U E S T I O N SP A R T BA N S W E R T W O 2 )Q U E S T I O N S O N L Y O U T O FF O U R ( 4) Q U E S T I O N S

THIS QUESTION PAPER CONSISTS OF 7 PAGES


2/7

B P B 2 0 8 3

PA RI A 50 marks)Q l As a quality offic er at HIJ Fertilizer Sdn. Bhd., you have collected filling processdata for bags of nitrogen fertilizer in your factory to determine the state of itsquality control. The data were collected in subgroup sizes of 6. Table Ql showsthe average and range of the fertilizer bags in kilogram.

Table Ql: Average and range of fertilizer bags (kilogram)

(a)

(b)

(c)

d)

Sample x-bar R Sample x-bar R1 20.35 0.34 14 20.41 0.362 20.40 0.36 15 20.45 0.343 20.36 0.32 16 20.34 0.364 20.65 0.36 17 20.36 0.375 20.20 0.36 18 20.42 0.736 20.40 0.35 19 20.50 0.387 20.43 0.31 20 20.31 0.358 20.37 0.34 21 20.39 0.389 20.48 0.30 22 20.39 0.3310 20.42 0.37 23 20.40 0.32

20.39 0.29 24 20.41 0.3412 20.38 0.30 25 20.40 0.3013 20.40 0.33

* Note: Round all calculations to two decimaCalculate the trial central line and control limits.

points

(7 marks)Calculate revised central line and control limits with the assumption thatcauses of defects are assignable if any points in Ql(a) are out of control.

(8 marks)Develop the revised x-bar and R charts.

(5 marks)Evaluate the state of quality control in filling bags of fertilizers in Ql(a)an dQ (b) by referring to the points which are outside of the control limits.

(5 marks)

2


3/7

B P B 2 0 8 3

Global competition and economic liberalization are creating opportunities forMalaysian organizations. They use quality to compete with other organizations toimprove their market share. Total Quality Management (TQM) is one of theimportant quality techniques which many firms are using to succeed. In addition,it has been widely implemented throughout the world across different industriesand sectors.The implementation of TQM has given positive result but some organizations findit difficult to implement it in a satisfactory and efficient way. They also noticedsome barriers or obstacles which hinder the implementation o fT Q M .Discuss SIX (6) barriers to TQM implementation that prevent organizations fromachieving the benefits expected from it. (25 marks)


4/7

B P B 2 0 8 3

PAR T B 50 marks)Q3 The variation concept is the law of nature in that no two natural items in any

categories are the same. Variation is present in every manufacturing process dueto a combination of equipment, materials, environment, and operator.Discuss FOU R 4) sources of variation in manufacturing process with an examplefor each source.

(25 marks)

Q4 Sunw ay Lagoon Sdn. Bhd. wants to maintain the pH value for swim ming poolwater of its theme park. One reading is taken each day for 20 days as shown inTable Q4.

Table Q4: pH value of swimming pool waterSam pel pll Sam pel pl l

1 4.56 4.582 4.65 12 4.713 4.66 13 4.614 4.34 14 4.665 4 .65 15 4.466 4.40 16 4.707 4.50 17 4.658 4.55 18 4.619 4.69 19 4.5410 4.29 20 4.55

*Note: Round all calculations to three decimal points.(a) Calcula te the central line and control limits using mov ing average andmoving range method with n = 3.

(10 marks)(b) Calcu late the central line and control limits for a period of 4 using thesame method in Q4(a).

(10 marks)(c) Explain the differe nces between the trial central line and control limits ofthe water pH value in Q4(a) and Q4(b).

(5 marks)

4


5/7

B P B 2 0 8 3

A p chart is used in quality control to report the fraction or percent ofnonconforming in a product, quality characteristic, or group of qualitycharacteristics. Table Q5 shows the data for the payment of insurance claims.' fable Q 5: Number of conformance of insurance claims payment

Sam pel Number of Number ofSam pel Inspected Noncon forming1 1750 472 1750 423 1750 484 1750 585 1750 326 1750 387 1750 538 1750 689 1750 4510 1750 371 1750 5712 1750 3813 1750 5314 1750 3715 1750 3916 1750 5117 1750 4418 1750 6119 1750 4820 1750 5621 1750 4822 1750 4023 1750 4724 1750 2525 1750 35

*Note: Round all calculations to four decimal points.Using the data:(a) Calcu late the trial central line and control limits for a p chart.

(10 marks)(b) Plot the trial central line and control limits values for a /; chart on graphpaper.

(5 marks)(c) Calcula te the revised central line and control limits if there are any out-of-control points in Q5(b) with the assumption that causes of defects areassignable.

(10 marks)

5


6/7

B P B 2 0 8 3

Q6 The ZZ-400 manu facturin g team used an affinity diagram to organize its list ofpotential performance indicators of its operations. Because the team works a shiftschedule and members could not meet to do the affinity diagram together, theymodified the procedure. They wrote each idea on a sticky note and put all thenotes randomly on a rarely used door. Table Q6 shows the list that the teammembers brainstormed.Table Q6: List of potential performance indicators

Possible Performance Measures% purity of OSHA recordable% trace metals of custom er returnsMaintenance costs Customer complaints

of emergency jobs Overtime/total hours workedlbs. Produced $/Ib. producedEnvironmental accidents Raw material utilizationMaterial costs YieldOve rtime costs Utility cost

of pum seal failures ppm waterViscosity ColorCpk values Service factorSafety Time between turnaroundsDays since last lost-time Hours wor ked/em ployee% rework or reject lbs. WasteHours downtime Housekeeping score% uptime % capacity field

As the quality manager of the ZZ-400, you have reviewed and organized the notesinto five major groups (product quality, maintenance, manufacturing cost, safetyand environmental, and volume).Develo p an affinity diagram for each group.

(25 marks)

EN D OF QU ESTION PA PER

6


7/7

B P B 2 0 8 3

Appendix i

FINAL EXAMINATIONSEM ESTE R/ SES SION : SEME STER I I /09 / 10 COU RSE: 2 BPA/ 2 BPBS U B J E C T : T O T A L Q U A L I T Y M A N A G E M E N T S U B J E C T C O D E : B P B 2 0 83

Factors for Computing Central Lines and 3a Control Limits for Variable ChartsSample CHA RT FOR CHART FOR STAND ARD DEVIATIONSSize A V E R A G E S

Factors for Control Factor for Central Factors for Control LimitsLimits Linen A2 As c , B B42 1.880 2.659 0.7979 0 3.267j 1.023 1.954 0.8862 0 2.5684 0.729 1.628 0.9213 0 2.2665 0.577 1.427 0.9400 0 2.0896 0.483 1.287 0.9515 0.030 1.9707 0.419 1.182 0.9594 0.1 18 1.8828 0.373 1.099 0.9650 0.185 1.815

CHART FOR RANGESCHART FOR AVERAGESCHART FOR STANDARD DEVIATIONS Chart forMediansSampleSize

Factor forCentral Line Factors for Control Limits

Chart forMedians

N d2 D3 D 1 D S D6 As2 1.128 0 3.267 0 3.865 2.224J 1.693 0 2.574 0 2.745 1.2654 2.059 0 2.282 0 2.375 0.8295 2.326 0 2.1 14 0 2.179 1.7126 2.534 0 2.004 0 2.055 0.5627 2.704 0.076 1.924 0.078 1.967 0.5208 2.847 0.136 1.864 0.139 1.901 0.441

7

ent.uthm.edu

Documents