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Quality Management “Excel Sheet”

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Problem 1, 10 points
The failure rate for a product is 7.39646E-07units per hour and the design engineers believe that it
is steady from 100 hours to 80,600 hours of product life. If you only wanted to replace0.029823proportion
of the product due to warranty claims: 1) how long would your warranty period be, 2) what would you do
about the fact that the rate of failure is not steady until after 100 hours of operation, and 3) briefly, (one or two 
short sentences) discuss what else you would put in the warranty relative to reliability?
Problem 2, 15 points
Step 1Step 2Step 3Step 4
0.9705440.9748475620.9616030.988281
R10000R11000R12000R10000
0.97106174
R9000
0.988197798
R10000
What is the R10000 reliability of the above system? A signal travels from left to right and, in step two, can go through any of the three
units working in parallel. 
Problem 3, 38 points0.172327
Design engineers have set product specifications at 60 mm/sec +/-.8 mm/sec. You know that product which measures
+/- .8 mm/sec from the mean costs the company an extra $ 31.72 per unit. You also know that it will cost you $ 9.52 per unit to adjust
a product to 60 mm/sec. You also know that your process is a 3 sigma process and the mean is  0.39SD lessthan
the target. The firm accepts Taguchi’s loss function as a viable means of modeling costs. How much is your 
process 1) currently costing you if you do nothing, 2) if you fix those that make  sense to fix? Would you spend  7.689308million
dollars to create a centered process with a Cp ranging from 1.5 to 2? If you did have such a process, would you adjust or not adjust
 (support using Taguchi’s cost function)? Production is 100340units per month (accrue monthly), costs $5000 per month to 
inspect each unit, productive life cycle of the product is projected to be 4.516981years, and the discount rate is expected to range from
9% to 15%APR. Support your answer both quantitatively (95% CL, n = 50) and qualitatively (six stake holder consideration). 
Problem 4 (3 points)) What decision do you make relative to control charts when you know the costs of Type I and Type II errors?
 
Problem 5 (2 points) What is the purpose of step 18 in the process of creating a QCP? 
Problem 6, 38 pointstakt time is 2.3447minutes, work 24/7/36530.41667days in a month
Specifications are .5″. +/- .001 inches, it costs386.16dollars when product is below the lower tolerance and 58.62dollars
labor and $100 per .001 inch  to bring those above the upper tolerance to 1 SD below tolerance.  The SD of the process is0.000281.
I can also change the system to a 5 to 6 sigma process for 2.344654million dollars. The organization accrues monthly, has a discount
rate that varies between 10 and 15% APR, looks only 3 years into the future on any project, is spending an additional $7000/month to inspect the
product, if put in the new system will spend only $2000 to control the process, currently the machine is set to produce a mean that is on target. 
Is there a business rule you could change currently to save money with the system as is, and what should that rule be if there is one? Should 
you alter the system to reduce the SD, show your answer as a 95% confidence interval using a sample of 50. Do not forget to judge your decision
from the perspectives of all stakeholders.
 
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