305EMM Total Quality Management 2020/2021 Statistical Process Control Improvement Program and Quality Costing Submission Date 14 June 2021

305EMM Total Quality Management 2020/2021
Statistical Process Control; Improvement Program and Quality Costing

Submission Date 14th June 2021
Assessment : TQM- SPC, Improvement Program and Quality costing
Submission Date: 14th June 2021
Late submissions will be penalised in accordance with University/Faculty policy
Learning Objectives (Numbering from MID):
3. Design a quality improvement program, select and identify suitable tools and techniques.
Discuss the importance of performance measurement and explain how performance measurement
system, benchmarking, and other techniques can help a company achieve continuous improvement.
4. Compare the different approaches to quality costing and evaluate the effectiveness of these
methods.
7. Explain variation, apply SPC to a simple example and calculate process capability. Plan the
implementation of SPC in a manufacturing organisation.
Procedure.
This is an individual assignment. Submission is online via Moodle (Submission automatically through
Turnitin link).
Student Effort.
It is estimated that you should spend approximately 25-30 hours on this assignment. The written
element of the assessment is expected to be no more than 3000 words.
Assessment.
The marks will be allocated as shown below. In addition:
Section A: marks will be awarded for detailed, accurate explanations and comments along with
accuracy of calculations and completeness of charts.
Section B: All quotes and additional sources of information must be fully referenced. The following
marking scheme will be applied. References and bibliography are not included in the page limit.
Overall clarity and structure of the report.
Plagiarism.
Any suspected cases of plagiarism or collusion will be dealt with via Coventry University disciplinary
procedures.
Do not “cut and paste” paragraphs/chapters from sources of literature.
All quotes, figures, illustrations etc must be correctly referenced.
Marking scheme.
100-70% Outstanding. An exceptional level of ability. No weaknesses.

69-60% Very Good. A high level of ability, no major weaknesses. Clear
Understanding of the project brief.
59-50% Good. Overall good level of ability. Weakness in some areas offset by
Strengths in others.
49-40% Fair. Overall minimum standard achieved. There may be competence
in some aspects, but performance may be below standard on other aspects.
<40% Unsatisfactory. Most aspects below the required standard. There are serious
shortcomings in coverage, content and approach.
1
Assignment Brief.
Section A: SPC theory

1. Your process has a normal histogram with mean located at 10 mm, 1s points at 9.9 and 10.1 mm, 2s points at
9.8 and 10.2 mm, and 3s points at 9.7 and 10.3 mm.
a. Construct a histogram and discuss the importance of sigma as a measure of variation.
(8 marks)
b. If your customer will accept parts measuring between 9.7 and 10.3 mm, how many parts of every 1,000
produced would you expect to scrap? What would have to be done to bring the scrap rate down to what
it had been at the former customer specification?
(7 marks)
2.
What is “Goalpost Mentality”? Why does it give producers false hope that they are satisfying their customers?
What is a better way of looking at your performance capability?
(10 marks)
3.
In developing a control chart, the analyst recognizes that there are two types of variation in a system. Specify the
types of variation. Explain the difference and what should be done to eliminate these variations
(5 marks)
4
The following results were obtained by taking samples of five (5) items at regular intervals.
Sample # observation
1 74.030 74.002 74.019 73.992 73.999
2 73.989 74.000 73.992 73.995 74.000
3 73.998 74.002 74.05 73.989 74.030
4 74.005 74.030 73.995 74.000 73.990
5 74.006 73.990 74.004 73.998 74.002
6 73.982 73.984 73.998 73.999 73.995
7 74.003 74.002 74.008 73.992 73.999
8 73.989 74.001 74.001 73.998 74.000
9 73.998 74.002 74.001 73.989 74.030
10 74.005 74.021 73.995 73.990 73.993
11 74.004 73.995 74.004 73.998 74.002
12 73.982 73.984 73.998 73.999 73.995
13 74.006 73.998 74.005 73.998 74.000
14 73.998 73.995 73.998 73.982 74.006
15 74.000 74.005 73.982 73.998 74.006
16 73.998 74.030 73.998 74.000 74.002
17 74.005 74.006 73.995 74.000 73.998
18 74.006 73.998 74.000 74.030 73.982
19 74.005 73.998 74.006 74.005 73.998
20 73.998 73.993 73.995 74.006 74.005
2
a) Construct control charts for the sample means and ranges showing the control limits and
comment on the results.
When sample size (n) 2 3 4 5

A2 1.880 1.023 0.729 0.577
D2 1.128 1.693 2.059 2.326
D3 0 0 0 0
D4 3.268 2.574 2.282 2.114
(10 marks)
b) The specification asks for a tolerance of 74inch +/- .04inch. Calculate the process capability
indices Cp and Cpk and comment on these. What level of process capability should you strive to
achieve for Cp and Cpk.
(10 marks)
Section B: SPC Implementation

4
Read the texts listed (below) on SPC implementation and other appropriate texts.
Antony, J., Balbontin, A. and Taner, T. (2000), “Key ingredients for the effective implementation
of statistical process control”, Work Study, Vol.49 No.6, pp.242-247.
Does, R.J., Schippers, W.A.J. and Trip, A. (1997), “A framework for implementation of statistical
process control”, International Journal of Quality Science, Vol 2, No. 3, 181-198.
The above documents are available electronically via the University Library electronic databases.
You are the Quality Manager in an electric car manufacturing company and feel it is time to
implement some form of improvement programme. Describe your recommendations in a report to the
Directors, which must include:
1. A method for implementing SPC across the company, including pre-requisites for
implementation, the implementation process and procedures to follow to ensure that the
benefits of SPC can be achieved. This should be in the form of a flow chart with an additional
1 page justification. (20 marks)
2. A summary of one relevant tool/technique which could be applied alongside statistical process
control and its benefits. (10 marks)
3. Select a quality costing method and analyse the benefits this technique could bring to the
company and also evaluate any issues with the quality costing method. (10 marks)
4. Overall structure and clarity of the report (10 marks)
You will need to make assumptions about the company, state these clearly.
3
Flow Diagram Example with notes and document links.

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305EMM Total Quality Management 2020/2021

Statistical Process Control; Improvement Program and Quality Costing

Learning Objectives (Numbering from MID):

100-70% Outstanding. An exceptional level of ability. No weaknesses.

Section A: SPC theory

When sample size (n) 2 3 4 5

Section B: SPC Implementation

4. Overall structure and clarity of the report (10 marks)

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