% Contribution

PARETO TABLE
No. of Failures % Cumulative
PARETO ANALYSIS OF WIRE FAILURE
Cause due to this Contribution % 120.00
cause
100.00
BW 359 45.39 45.39
80.00
CCF 141 17.83 63.21
Rough 136 17.19 80.40 60.00

EF 62 7.84 88.24 40.00

ODOS 45 5.69 93.93 20.00

CV 29 3.67 97.60
0.00
Others 19 2.40 100.00 BW CCF Rough EF ODOS CV Others
TOTAL 791 100 100.00 Cause of Failure
 Frequency Distribution of Bare Copper Wire Diameter
HISTOGRAM OF WIRE DIAMETER
Class Interval Mid Value Frequency % Data
(X) (f) Distribution 50
45
1.3815 - 1.3845 1.383 1 0.83 40

Frequency (Nos)
35
1.3845 - 1.3875 1.386 2 1.67 30
1.3875 - 1.3905 1.389 14 11.67 25
20
1.3905 - 1.3935 1.392 18 15.00 15
1.3935 - 1.3965 1.395 47 39.17 10
5
1.3965 - 1.3995 1.398 33 27.50 0
1.3995 - 1.4025 1.401 5 4.17 1.383 1.386 1.389 1.392 1.395 1.398 1.401
Diameter (mm)
TOTAL : 120
DIAMETER

92 1.395 1.398 1.401

(mm)
 p-Chart

Fraction Defective (p)

Sample Number of Fraction
Sample No: Size (n) Defectives Defective (p) LCL(p) CL(p) UCL(p)
1 92 6 0.07 0.00 0.06 0.13
2 36 1 0.03 0.00 0.06 0.18
3 212 41 0.19 0.01 0.06 0.11 p-chart
4 86 13 0.15 0.00 0.06 0.14 0.30
5 172 35 0.20 0.01 0.06 0.11
6 448 40 0.09 0.03 0.06 0.09 0.25
7 564 22 0.04 0.03 0.06 0.09
8 48 0 0.00 0.00 0.06 0.16 0.20
9 594 3 0.01 0.03 0.06 0.09
0.15
10 530 14 0.03 0.03 0.06 0.09
11 188 9 0.05 0.01 0.06 0.11
0.10
12 15 3 0.20 0.00 0.06 0.24
13 97 2 0.02 0.00 0.06 0.13 0.05
14 36 0 0.00 0.00 0.06 0.18
15 65 5 0.08 0.00 0.06 0.15 0.00

10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
7
8
9
16 54 3 0.06 0.00 0.06 0.16
17 82 8 0.10 0.00 0.06 0.14
Sample No.
18 67 3 0.04 0.00 0.06 0.15 Fraction Defective (p) LCL(p) UCL(p) CL(p)
19 18 0 0.00 0.00 0.06 0.23
20 52 4 0.08 0.00 0.06 0.16
21 72 6 0.08 0.00 0.06 0.14
22 96 0 0.00 0.00 0.06 0.13
N D pbar
Totals 3624 218 0.06

Formulae for Control Limit calculation:

CL(p) = pbar
LCL(p) = pbar - 3 * Sqrt ( pbar (1-pbar) / n )
UCL(p) = pbar + 3 * Sqrt ( pbar (1-pbar) / n )
 16

CL(p)
17
18
19
20

CL(p)
21
22
 np-Chart
Sample Number of

No. of Defectives / Sample

Sample No: Size (n) Defectives LCL(np) CL(np) UCL(np)
1 50 2 0 2.86 7.79 Defectives (np) Chart
2 50 4 0 2.86 7.79
3 50 4 0 2.86 7.79
4 50 3 0 2.86 7.79 9
5 50 6 0 2.86 7.79
6 50 2 0 2.86 7.79 8
7 50 3 0 2.86 7.79
8 50 0 0 2.86 7.79 7
9 50 0 0 2.86 7.79
10 50 3 0 2.86 7.79 6
11 50 1 0 2.86 7.79
12 50 5 0 2.86 7.79 5
13 50 4 0 2.86 7.79
14 50 7 0 2.86 7.79 4
15 50 3 0 2.86 7.79
16 50 2 0 2.86 7.79 3
17 50 4 0 2.86 7.79
18 50 1 0 2.86 7.79 2
19 50 0 0 2.86 7.79
20 50 5 0 2.86 7.79
1
21 50 3 0 2.86 7.79
22 50 1 0 2.86 7.79
0
N D pbar npbar 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Totals 1100 63 0.06 2.86
Sample No.
Number of Defectives LCL(np)
Formulae for Control Limit calculation:
CL(np) UCL(np)
CL(np) = npbar = 2.86
LCL(np) = npbar - 3 * Sqrt ( npbar (1-pbar) ) = 0
UCL(np) = npbar + 3 * Sqrt ( npbar (1-pbar) ) = 7.79
art

4 15 16 17 18 19 20 21 22
 c-Chart
Sample No. of
Sample No: Size (n) Defects, c LCL( c ) CL( c ) UCL( c )
1 1 9 0 4.86 11.48 Defects (c) Chart
2 1 12 0 4.86 11.48 16
3 1 7 0 4.86 11.48
4 1 7 0 4.86 11.48 14
5 1 8 0 4.86 11.48
6 1 14 0 4.86 11.48 12
7 1 3 0 4.86 11.48
8 1 5 0 4.86 11.48 10

No. of Defects
9 1 6 0 4.86 11.48
10 1 6 0 4.86 11.48 8
11 1 4 0 4.86 11.48
6
12 1 1 0 4.86 11.48
13 1 3 0 4.86 11.48 4
14 1 2 0 4.86 11.48
15 1 4 0 4.86 11.48 2
16 1 3 0 4.86 11.48
17 1 0 0 4.86 11.48 0
18 1 5 0 4.86 11.48 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
19 1 1 0 4.86 11.48
20 1 2 0 4.86 11.48 Sample No.
No. of Defects, c LCL( c ) CL( c ) UCL(
21 1 4 0 4.86 11.48
22 1 1 0 4.86 11.48
N C cbar
Totals 22 107 4.86

Formulae for Control Limit calculation:

CL( c ) = cbar = 4.86
LCL( c ) = cbar - 3 * Sqrt ( cbar ) = 0
UCL( c ) = cbar + 3 * Sqrt ( cbar ) = 11.48
4 15 16 17 18 19 20 21 22

CL( c ) UCL( c )
 Xbar - Range Chart
Sample
Data (Sample Size, n = 4) Average, Sample
Sample No: Xbar Range, R LCL(R) CL(R) UCL(R) LCL(Xbar) CL(Xbar) UCL(Xbar)
0.5160
1 0.511 0.510 0.510 0.508 0.5098 0.0030 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.5140

Sample Average (Xbar)

2 0.510 0.507 0.503 0.509 0.5073 0.0070 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.5120
3 0.513 0.511 0.516 0.520 0.5150 0.0090 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.5100
0.5080
4 0.514 0.512 0.513 0.510 0.5123 0.0040 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.5060
5 0.512 0.504 0.505 0.520 0.5103 0.0160 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.5040
6 0.512 0.508 0.505 0.507 0.5080 0.0070 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.5020
0.5000
7 0.513 0.510 0.512 0.511 0.5115 0.0030 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.4980
8 0.508 0.508 0.512 0.511 0.5098 0.0040 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 1 2 3
9 0.510 0.511 0.508 0.507 0.5090 0.0040 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136
10 0.512 0.511 0.515 0.509 0.5118 0.0060 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 Sample Average, X
UCL(Xbar)
11 0.512 0.514 0.509 0.513 0.5120 0.0050 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136
12 0.510 0.511 0.508 0.514 0.5108 0.0060 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136
13 0.507 0.505 0.500 0.503 0.5038 0.0070 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136
14 0.507 0.504 0.509 0.512 0.5080 0.0080 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136
0.0180
15 0.508 0.512 0.506 0.511 0.5093 0.0060 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.0160
16 0.514 0.510 0.508 0.510 0.5105 0.0060 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.0140

Sample Range (R)

0.0120
17 0.502 0.507 0.504 0.507 0.5050 0.0050 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.0100
18 0.510 0.505 0.511 0.511 0.5093 0.0060 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.0080
19 0.511 0.507 0.509 0.508 0.5088 0.0040 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.0060
0.0040
20 0.512 0.507 0.512 0.510 0.5103 0.0050 0.0000 0.0055 0.0126 0.5055 0.5096 0.5136 0.0020
XDbar Rbar 0.0000
Average 0.50960 0.0061 1 2 3

Sa
DATA HOMOGENISATION AND CALCULATION OF CONTROL LIMITS

Formulae for Control Limit calculation:

For n=4,
d2 = 2.059 D3 = 0.000
 A2 = 0.729 D4 = 2.282

RANGE HOMOGENISATION: ITERATION - 01

CL(R) = Rbar = 0.00605 CL(Xbar) = XDbar = NA

LCL(R) = D3 * Rbar = 0.00000 LCL(Xbar) = XDbar - A2 * Rbar = NA
UCL(R) = D4 * Rbar = 0.01381 UCL(Xbar) = XDbar + A2 * Rbar = NA

As the sample range is beyond control limits for sample No. 5, this sample is dropped.

RANGE HOMOGENISATION: ITERATION - 02

Now, re-calculate Rbar, Xdbar, and control limits with the remaining 19 samples.

Rbar' = 0.0055 Xdbar' = 0.5096

CL(R) = Rbar' = 0.00553 CL(Xbar) = Xdbar' = 0.50957

LCL(R) = D3 * Rbar' = 0.00000 LCL(Xbar) = Xdbar' - A2 * Rbar' = 0.50554
UCL(R) = D4 * Rbar' = 0.01261 UCL(Xbar) = Xdbar' + A2 * Rbar' = 0.51359

As all the 19 ranges fall within the new control limits, new Rbar value is accepted.

Data homogenisation is completed with this 2nd iteration. Use new control limits.

Process Sigma = Rbar' / d2 = 0.00268

 XBar Chart
0.5160
0.5140
Sample Average (Xbar)

0.5120
0.5100
0.5080
0.5060
0.5040
0.5020
0.5000
0.4980
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample No.
Sample Average, Xbar LCL(Xbar) CL(Xbar)
UCL(Xbar)

Range Chart
0.0180
0.0160
0.0140
Sample Range (R)

0.0120
0.0100
0.0080
0.0060
0.0040
0.0020
0.0000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Sample No.

Sample Range, R LCL(R) CL(R) UCL(R)

 X - MR Chart

Sample Moving X - Cha

Sample No: Size (n) Data (X) Range (MR) LCL(MR) CL(MR) UCL(MR) LCL(X) CL(X) UCL(X) 5.500
1 1 4.25 0 0.282 0.921 3.475 4.224 4.973 5.000
2 1 4.78 0.53 0 0.282 0.921 3.475 4.224 4.973
4.500
3 1 3.95 0.83 0 0.282 0.921 3.475 4.224 4.973
4.000

Data (X)
4 1 3.86 0.09 0 0.282 0.921 3.475 4.224 4.973
5 1 3.72 0.14 0 0.282 0.921 3.475 4.224 4.973 3.500
6 1 4.17 0.45 0 0.282 0.921 3.475 4.224 4.973 3.000
7 1 4.37 0.20 0 0.282 0.921 3.475 4.224 4.973 2.500
8 1 4.65 0.28 0 0.282 0.921 3.475 4.224 4.973 2.000
9 1 4.70 0.05 0 0.282 0.921 3.475 4.224 4.973 1 2 3 4 5 6 7 8 9 Sam
1
10 1 4.35 0.35 0 0.282 0.921 3.475 4.224 4.973
11 1 4.18 0.17 0 0.282 0.921 3.475 4.224 4.973 Data (X) LCL(X) CL(X)
12 1 4.76 0.58 0 0.282 0.921 3.475 4.224 4.973
13 1 4.50 0.26 0 0.282 0.921 3.475 4.224 4.973
14 1 4.20 0.30 0 0.282 0.921 3.475 4.224 4.973 Moving R
15 1 4.10 0.10 0 0.282 0.921 3.475 4.224 4.973 1.000
16 1 3.90 0.20 0 0.282 0.921 3.475 4.224 4.973 0.800

Moving Range (MR)

17 1 4.20 0.30 0 0.282 0.921 3.475 4.224 4.973
18 1 4.00 0.20 0 0.282 0.921 3.475 4.224 4.973 0.600
19 1 3.84 0.16 0 0.282 0.921 3.475 4.224 4.973 0.400
20 1 4.00 0.16 0 0.282 0.921 3.475 4.224 4.973
Xbar MRbar 0.200
Average 4.22 0.28158 0.000
Formulae for Control Limit calculation: 1 2 3 4 5 6 7 8 9
Sa
CL(MR) = MRbar = 0.282 CL(X) = Xbar = 4.224
LCL(MR) = 0 = 0.000 LCL(X) = Xbar - 2.66 * MRbar = 3.475 Moving Range (MR) LCL(MR)
UCL(MR) = 3.27 * MRbar = 0.921 UCL(X) = Xbar + 2.66 * MRbar = 4.973 CL(MR) UCL(MR)

Note: In this example, no data were dropped during Homogenisation.

 X - Chart

5 6 7 8 9 Sample
10 No.
11 12 13 14 15 16 17 18 19 20

LCL(X) CL(X) UCL(X)

Moving Range Chart

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample No.

LCL(MR)
UCL(MR)