Statistical quality control for large lots: For high-volume production, statistical methods (e.g., sampling plans, SPC) may be used so that only a sample of parts is inspected to control quality. Evaluate this practice.

Difficulty: Easy

Correct Answer: Correct

Explanation:


Introduction / Context:
Inspecting every single unit (100% inspection) can be costly and sometimes less effective than statistically designed sampling. In mass production, statistical quality control (SQC), acceptance sampling, and statistical process control (SPC) are widely used to monitor and maintain quality with manageable effort.



Given Data / Assumptions:

  • Production lot sizes are large, making 100% inspection impractical.
  • The process is stable enough to be monitored statistically.
  • Risk levels (producer’s and consumer’s) are defined for acceptance sampling.


Concept / Approach:
Sampling plans (e.g., ANSI/ASQ Z1.4) define how many parts to inspect and the acceptance criteria. SPC charts track process variation in real time to prevent defects. These methods reduce inspection burden, focus on process capability, and can deliver better overall quality than exhaustive inspection that may miss systemic issues.



Step-by-Step Solution:

Establish process stability and capability (Cp, Cpk).Select an acceptance sampling plan with defined AQL and LTPD risk levels.Implement SPC charts (e.g., X-bar, R) at key operations to detect shifts early.Continuously improve the process to lower defect rates and sampling intensity.


Verification / Alternative check:

Audit scrap, rework, and customer returns before and after SPC adoption to confirm effectiveness.


Why Other Options Are Wrong:

Incorrect: Statistical methods are industry-standard for large-batch control.Permitted only for safety-critical items / Valid only when 100% inspection is cheaper: Usage depends on risk and economics, not only on those conditions.


Common Pitfalls:

Using sampling without ensuring the process is stable.Misinterpreting control chart signals and allowing special causes to persist.


Final Answer:

Correct

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