/*! This file is auto-generated */ .wp-block-button__link{color:#fff;background-color:#32373c;border-radius:9999px;box-shadow:none;text-decoration:none;padding:calc(.667em + 2px) calc(1.333em + 2px);font-size:1.125em}.wp-block-file__button{background:#32373c;color:#fff;text-decoration:none} Problem 23 Product quality assurance (QA) i... [FREE SOLUTION] | 91Ó°ÊÓ

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Product quality assurance (QA) is a particularly tricky business in the dye manufacturing industry. A slight variation in reaction conditions can lead to a measurable change in the color of the product, and since customers usually require extremely high color reproducibility from one shipment to another, even a small color change can lead to rejection of a product batch. Suppose the various color frequency and intensity values that comprise a color analysis are combined into a single numerical value, \(C\), for a particular yellow dye. During a test period in which the reactor conditions are carefully controlled and the reactor is thoroughly cleaned between successive batches (not the usual procedure), product analyses of 12 batches run on successive days yield the following color readings: $$\begin{array}{|l|c|c|c|c|c|c|c|c|c|c|c|c|}\hline \text { Batch } & 1 & 2 & 3 & 4 & 5 & 6 & 7 & 8 & 9 & 10 & 11 & 12 \\ \hline C & 74.3 & 71.8 & 72.0 & 73.1 & 75.1 & 72.6 & 75.3 & 73.4 & 74.8 & 72.6 & 73.0 & 73.7 \\\\\hline\end{array}$$ (a) The QA specification for routine production is that a batch that falls more than two standard deviations away from the test period mean must be rejected and sent for reworking. Determine the minimum and maximum acceptable values of \(C\) (b) A statistician working in quality assurance and a production engineer are having an argument. One of them, Frank, wants to raise the QA specification to three standard deviations and the other, Joanne, wants to lower it to one. Reworking is time-consuming, expensive, and very unpopular with the engineers who have to do it. Who is more likely to be the statistician and who the engineer? Explain. (c) Suppose that in the first few weeks of operation relatively few unacceptable batches are produced, but then the number begins to climb steadily. Think of up to five possible causes, and state how you might go about determining whether or not each of them might in fact be responsible for the drop in quality.

Short Answer

Expert verified
The range of acceptable values of 'C' can be calculated using mean and a two-standard-deviation rule. The employee advocating for a larger specification range is likely the engineer, while the one advocating for a smaller range is likely the statistician. The increasing number of unacceptable batches could be due to factors such as equipment degradation, changes in raw material quality, or changing environmental conditions.

Step by step solution

01

Calculate the Mean

First, calculate the mean or average color reading during the test period. Add all the individual 'C' values together and then divide by the total number of batches. This provides the 'average' or 'expected' color reading.
02

Calculate the Standard Deviation

Next, calculate the standard deviation, which is a measure of the amount of variation from the mean. To do this, subtract each batch's color reading from the mean calculated in the previous step, then square the result, sum them up, and divide by the number of batches. Take the square root of the result to get standard deviation.
03

Calculate Acceptable Range

Once you have the mean and standard deviation, calculate the minimum and maximum acceptable values of 'C', denoting the acceptable range of color readings. For this particular quality assurance setup, a batch is rejected if it deviates more than two standard deviations from the mean, so subtract two times the standard deviation from the mean to get the minimum value, and add two times the standard deviation to the mean to get the maximum value.
04

Identify the Statistician and Engineer

Now, apply logical reasoning to identify Frank and Joanne's roles. The one who wants to raise the specification, making it less tight, is more likely the engineer due to their concern to reduce reworking. The one advocating a lower specification, making the standard more stringent and thus more aligned with quality control and statistical practices, is likely the statistician.
05

Identify Possible Causes and Solutions

Finally, to answer the last part of the question, first, brainstorm up to five possible causes for an increase in unacceptable batches over time and then propose ways to determine whether these are the actual reasons for the drop in quality. A few examples could be degradation of equipment over time, changes in raw materials quality, or changes in ambient conditions. These causes can be investigated respectively by mechanical inspection, evaluating new suppliers or materials, and analyzing environmental factors such as temperature or humidity.

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Key Concepts

These are the key concepts you need to understand to accurately answer the question.

Standard Deviation in Quality Control

In chemical process quality assurance, understanding the role of standard deviation is crucial. It provides insight into how much variability exists around the mean or average product quality measurement. When chemical engineers calculate the standard deviation, they gain a quantitative measure of consistency across product batches. This figure represents the 'spread' of a set of readings about the central value. In the case of dye manufacturing, where consistent color intensity and frequency are critical, a low standard deviation means that most color readings are close to the mean, reflecting high quality and reproducibility.

To apply this concept to quality control in the chemical process, if we set a threshold of acceptable quality at two standard deviations from the mean, we are establishing a confidence interval, usually amounting to 95% for a normal distribution, within which we expect the vast majority of our product to fall. Batches outside of this range signify a notable deviation from the established norm and trigger further investigation or reworking. It's a balance between being stringent enough to assure quality and lenient enough to avoid excessive costs associated with reworking or discarding products.

Statistical Analysis in Chemical Engineering

Statistical analysis serves as a backbone for decision-making in chemical engineering, particularly in quality assurance. The essence of making an informed decision, such as determining QA specifications, involves employing statistical tools to interpret data and manage production quality. Statistical measures like mean and standard deviation inform engineers and statisticians about the performance and reliability of their chemical processes.

In the scenario provided, the decision to set the acceptable range of product quality to one, two, or three standard deviations from the mean impacts the rate at which batches are rejected and require reworking. The decision hinges on a trade-off between product quality and operational efficiency: more stringent control (one standard deviation) may lead to higher quality but also to higher operational costs, whereas more lenient control (three standard deviations) may reduce costs but also decrease overall product quality.

The argument between Frank and Joanne about setting the QA specification reflects this trade-off, with the person advocating for a tighter control being more aligned with the principles of statistical quality control, hence likely to be the statistician, and the one arguing for a more lenient approach focusing on reducing the non-value-adding work of reworks, likely representing the concerns of an engineer.

Troubleshooting Production Quality

Troubleshooting production quality issues involves a systematic approach to identifying the source of problems when product batches begin to fail QA checks with increasing frequency. The range of potential causes is wide; it could stem from equipment wear and tear, variability in raw materials, or even environmental fluctuations impacting sensitive chemical reactions.

Resolving such quality issues would first involve information-gathering stages using observational studies, historical batch records, and experimental methods to narrow down the likely culprits. Equipment can be inspected and serviced if deterioration is suspected. If raw material quality is in question, sample analyses are essential, perhaps matched with supplier audits. Lastly, for environmental influences, monitoring and controlling parameters like temperature and humidity could help return the product quality to its desired standards. Troubleshooting is inherently a detective work where each hypothesis must be validated or rejected through real-time data and process understanding.

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Most popular questions from this chapter

The temperature in a process unit is controlled by passing cooling water at a measured rate through a jacket that encloses the unit. The exact relationship between the unit temperature \(T\left(^{\circ} \mathrm{C}\right)\) and the water flow rate \(\phi(\mathrm{L} / \mathrm{s})\) is extremely complex, and it is desired to derive a simple empirical formula to approximate this relationship over a limited range of flow rates and temperatures. Data are taken for \(T\) versus \(\phi\). Plots of \(T\) versus \(\phi\) on rectangular and semilog coordinates are distinctly curved (ruling out \(T=a \phi+b\) and \(T=a e^{b \phi}\) as possible empirical functions), but a log plot appears as follows: A line drawn through the data goes through the points \(\left(\phi_{1}=25 \mathrm{L} / \mathrm{s}, T_{1}=210^{\circ} \mathrm{C}\right)\) and \(\left(\phi_{2}=40 \mathrm{L} / \mathrm{s},\right.\) \(\left.T_{2}=120^{\circ} \mathrm{C}\right)\). (a) What is the empirical relationship between \(\phi\) and \(T ?\) (b) Using your derived equation, estimate the cooling water flow rates needed to maintain the process unit temperature at \(85^{\circ} \mathrm{C}, 175^{\circ} \mathrm{C},\) and \(290^{\circ} \mathrm{C}\). (c) In which of the three estimates in Part (b) would you have the most confidence and in which would you have the least confidence? Explain your reasoning.

A solution containing hazardous waste is charged into a storage tank and subjected to a chemical treatment that decomposes the waste to harmless products. The concentration of the decomposing waste, \(C,\) has been reported to vary with time according to the formula \(C=1 /(a+b t)\) When sufficient time has elapsed for the concentration to drop to \(0.01 \mathrm{g} / \mathrm{L},\) the contents of the tank are discharged appropriately. The following data are taken for \(C\) and \(t\): $$\begin{array}{|c|c|c|c|c|c|}\hline t(\mathrm{h}) & 1.0 & 2.0 & 3.0 & 4.0 & 5.0 \\\\\hline C(\mathrm{g} / \mathrm{L}) & 1.43 & 1.02 & 0.73 & 0.53 & 0.38 \\\\\hline\end{array}$$ (a) If the given formula is correct, what plot would yield a straight line that would enable you to determine the parameters \(a\) and \(b ?\) (b) Estimate \(a\) and \(b\) using the method of least squares (Appendix A.1) or graphics software. Check the goodness of fit by generating a plot of \(C\) versus \(t\) that shows both the measured and predicted values of \(C\). (c) Using the results of Part (b), estimate the initial concentration of the waste in the tank and the time required for \(C\) to reach its discharge level. (d) You should have very little confidence in the time estimated in Part (c). Explain why. (e) There are potential problems with the whole waste disposal procedure. Suggest several of them. (f) The problem statement includes the phrase "discharged appropriately." Recognizing that what is considered appropriate may change with time, list three different means of disposal and concerns with each.

The following \((x, y)\) data are recorded: $$\begin{array}{|c|c|c|c|}\hline x & 0.5 & 1.4 & 84 \\\\\hline y & 2.20 & 4.30 & 6.15 \\\\\hline \end{array}$$ (a) Plot the data on logarithmic axes. (b) Determine the coefficients of a power law expression \(y=a x^{b}\) using the method of least squares. (Remember what you are really plotting \(-\) there is no way to avoid taking logarithms of the data point coordinates in this case.) (c) Draw your calculated line on the same plot as the data.

A horizontal drum, a cross-section of which is shown below, is being filled with benzene (density \(\left.=0.879 \mathrm{g} / \mathrm{cm}^{3}\right)\) at a constant rate \(\dot{m}(\mathrm{kg} / \mathrm{min}) .\) The drum has a length \(L\) and radius \(r,\) and the level of benzene in the drum is \(h\). The expression for the volume of benzene in the drum is \(V=L\left[r^{2} \cos ^{-1}\left(\frac{r-h}{r}\right)-(r-h) \sqrt{r^{2}-(r-h)^{2}}\right]\) (a) Show that the equation gives reasonable results for \(h=0, h=r,\) and \(h=2 r\). (b) Estimate the mass of benzene \((\mathrm{kg})\) in the tank if \(L=10 \mathrm{ft}, r=2 \mathrm{ft},\) and \(h=4\) in. (c) Suppose there is a sight glass on the side of the tank that allows observation of the height of liquid in the tank. Use a spreadsheet to prepare a graph that can be posted next to the sight glass so that an operator can estimate the mass that is in the tank without going through calculations like that in Part (b).

The following reactions take place in a batch reactor: \(\mathrm{A}+\mathrm{B} \rightarrow \mathrm{C}\) (desired product) \(\mathrm{B}+\mathrm{C} \rightarrow \mathrm{D}\) (hazardous product) As the reaction proceeds, D builds up in the reactor and could cause an explosion if its concentration exceeds 15 mol/L. To ensure the safety of the plant personnel, the reaction is quenched (e.g., by cooling the reactor contents to a low temperature) and the products are extracted when the concentration of \(D\) reaches \(10 \mathrm{mol} / \mathrm{L}\). The concentration of \(C\) is measured in real-time, and samples are periodically taken and analyzed to determine the concentration of D. The data are shown below: $$\begin{array}{|c|c|}\hline C_{\mathrm{C}}(\mathrm{mol} / \mathrm{L}) & C_{\mathrm{D}}(\mathrm{mol} / \mathrm{L}) \\ \hline 2.8 & 1.4 \\\\\hline 10 & 2.27 \\\\\hline 20 & 2.95 \\\\\hline 40 & 3.84 \\\\\hline 70 & 4.74 \\\\\hline 110 & 5.63 \\ \hline 160 & 6.49 \\\\\hline 220 & 7.32 \\\\\hline\end{array}$$ (a) What would be the general form of an expression for \(C_{\mathrm{D}}\) as a function of \(C_{\mathrm{C}} ?\) (b) Derive the expression. (c) At what concentration of \(C\) is the reactor stopped? (d) Someone proposed not stopping the reaction until \(C_{\mathrm{D}}=13 \mathrm{mol} / \mathrm{L},\) and someone else strongly objected. What would be the major arguments for and against that proposal?

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