Birla Institute of Technology & Science, Pilani Work-Integrated Learning Programmes Division B.

S Power Engineering First Semester 2012-2013 Course Handout Course No. : POWAB ZC312/POWES ZC312/POWTP ZC312

Course Title : QUALITY CONTROL ASSURANCE & RELIABILITY

Course Description Basic concepts of probability and probability distributions, standard probability distribution, sampling and sampling distributions, confidence intervals, testing significance, statistical tolerance, various types of control charts, statistical processes control techniques, value analysis, defect diagnosis and prevention, basic concepts of reliability, reliability design evaluation and control, methods of applying total quality management, production process. Scope and Objectives This course presents an exposition to the modern thoughts on quality and related practices. The principles and techniques for quality control based on statistical methods and the procedures for quality assurance are covered Tools for quality engineering and quality management are also covered. Concepts of reliability and methods to improve product and system reliability are dealt with. The course is tailored to enable practicing engineers to become successful managers to become successful managers in a sustained manner to provide business houses the leading edge. Prescribed Text Book
T1

Mitra Amitava, Fundamentals of Quality Control and Improvement, Prentice Hall of India, 2 nd Ed., 1998.

Reference Books
R1. R2. R3.

D.H. Besterfield et al., Quality Control, Pearson Education, 7th Ed., 2004 D.H. Besterfield et. al, Total Quality Management, Pearson Education, 2nd Edition, 2001. Douglas C. Montgomery, Introduction to Statistical Quality Control, John Wiley & Sons, 3rd Ed., 2001. James R. Evans, Total Quality Management, Organization, and Strategy, Thomson, 4th Ed., 2007. James R. Evans, William M. Lindsay, The Management and Control of Quality, Thomson, 6th Ed., 2006.

R4. R5.

POWAB ZC312 /POWES ZC 312/POWTP ZC312

Course Handout

First Semester 2012-2013

Page 2

Plan of Lecture and Self Study Lecture No. 1 Topics and Learning Objectives
Introduction, Evolution of quality control, Quality, Quality control, Quality assurance, Quality circle and quality improvement teams, Benefits of quality control, responsibility for quality, Reliability, Total quality system, Quality improvement, Quality costs, Measuring quality cost, Management of quality, Quality and Productivity, Total quality environmental management Some philosophies and their impact on quality: Introduction, W. Edwards Deming and his contribution, Extended process, Demings 14 points for management, P. Crosbys philosophy, The three philosophies compared Quality Management : Practices, Tools and standards: Introduction, Management Commitment, QFD, Innovative adaptation and performance evaluation, Tools for continuous quality improvement, International standards ISO 9000:9004,TS16949, Malcolm Baldrige National Quality Awards,

Chapter Reference

Introduction to Quality Control and Total Quality System: T1- Chapter 1

2&3

T1- Chapter 2

T1- Chapter 3

5&6

Fundamental of Statistical concepts and techniques in quality T1- Chapter 4 control and improvement: Introduction, Population and sample, Parameter and Statistics, Probability, Descriptive Statistics, Probability Distribution, Inferential Statistics, Concepts in Sampling Graphical methods of Data presentation and quality improvement: T1- Chapter 5
Introduction, Frequency distribution and Histograms, Run Charts, Stem and Leaf plots, Pareto Diagrams, Cause and Effect Diagrams, Box plots, Normal Probability plots, Empirical Quantile-Quantile plots, Scatter Diagrams, Multivariable charts, Matrix plots and Three dimensional Scatter Plots Statistical process control using control charts: Introduction, Causes of variations, Statistical basis for control charts, Selection of Rational Samples, Analysis of Patterns in Control Charts, Maintenance of Control Charts.

8 9 10 & 11

T1- Chapter 6

Review/Tutorial Session on lecture No. 1 to 8 Control chart for variables: Introduction, Selection of Characteristics for
Investigation, Preliminary Decisions, Control Charts for the Mean and Range, Control Charts for Mean and Standard Deviation, Control Charts for Individual Units, Other Control Charts, Multivariate Control Charts Control chart for attributes: Introduction, Advantages and Disadvantages of Attribute charts, Preliminary Decisions, Charts for Proportion Nonconforming(p-Chart) ,np-charts, c-chart, u-chart, U-chart, Operating characteristics curves for Attribute Control Charts Process capability analysis: Introduction, Specification limits and Control Limits, Process Capability Analysis, Natural Tolerance Limits, Specifications and Process Capability, Process Capability Indices, Process Capability Analysis Procedures, Setting Tolerances on Assemblies and components, Estimating Natural Tolerance Limits of a process.

T1- Chapter 7

12

T1- Chapter 8

13

T1- Chapter 9

POWAB ZC312 /POWES ZC 312/POWTP ZC312

Course Handout

First Semester 2012-2013

Page 3

Plan of Lecture and Self Study Lecture No. 14 & 15 Topics and Learning Objectives Acceptance sampling plans for attributes and variables: Introduction,
Advantages and Disadvantages of Sampling, Producers Risk and Consumers Risk, Operating Characteristics Curve, Types of Sampling Plans, Evaluating Sampling Plans, Lot-by-Lot Attribute Sampling Plans, Other Attribute Sampling Plans, Sampling Plans for Continuous Production, Demings kpRule, Sampling plans for Variables, Advantages and Disadvantages of Variable Plans, Variable Sampling Plans for Process Parameters, Variable Sampling Plans for for estimating the Lot Proportion Nonconforming, Standardized Plans Reliability: Introduction, Reliability, Life cycle curve and probability distributions in Modeling Reliability, System Reliability, Operating Characteristics Curves, Reliability and Life Testing Plans Quality control in service sector: Introduction, Service Industries and their characteristics, A Model for Service Quality, Appllications.

Chapter Reference T1- Chapter 10

16 17 18

T1- Chapter 11 T1- Chapter 13

Review/Tutorial Session on Lecture No. 10-17

Evaluation Scheme:
EC No 1. 2. 3. Components Assignment I Assignment II Compre. Exam Duration ---3 Hours Weightage 20% 20% 60% Date 10th Oct 2012 10th Nov 2012 Will be announced later Nature Take Home Take Home 40% Closed book (10 AM to 12 Noon) 20% Open Book (12 Noon to 1 PM)

Instructor-in-Charges