Challenge 1• The upper and lower control limits for the X-bar chart will be around34.5 and 25.5, respectively• For the R chart, the lower control limit will always be zero because D3is not defined for a sample size of 5• The upper control limit for the R chart will vary around about 16.5 Challenge 2• When Challenge 2 is run without making any interventions, the totalcost should be aroun
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Challenge 1
• The upper and lower control limits for the X-bar chart will be around
34.5 and 25.5, respectively
• For the R chart, the lower control limit will always be zero because D3
is not defined for a sample size of 5
• The upper control limit for the R chart will vary around about 16.5
Challenge 2
• When Challenge 2 is run without making any interventions, the total
cost should be around $14,000
When equipment recalibrations and labor substitutions are made
when assignable causes are detected, the total cost is reduced
substantially, to around $4000. Around $3500 of that amount is in
external defect costs, while the rest is in internal defect costs and the
cost of making the recalibrations and labor substitutions
Challenge 3
• Below is a summary of the process capability indices for each of the
scenarios. Cp was used for companies A and C, two sided Cpk was used
for company D, and one-sided Cpk was used for company B
Challenge 4
• When Challenge 4 is run without making any investments in improving
the quality of the process, the total cost of quality is around $41,000.
• This is comprised primarily of external failure costs, with a small amount
of internal failure costs and appraisal costs for the baseline sampling plan.
• At the other extreme, the cost of making the maximum investment in
each of the categories is about $17,500. Internal and external failure costs
will be zero or close to zero, with $15,000 invested in prevention and
$2500 invested in appraisal.
• Best results: $8750 via labor training = $1250, equipment = $4000,
Supplier = $3000, sample size = 5 and sample frequency = high.
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