Topic-1 Introduction To SQC

LectureNotesofStatisticalQualityControl(IM511)
IM 511
Statistical Quality Control

ResourcePerson
Dr.MuhammadWasif,PMP
AssistantProfessor
DepartmentofIndustrialandManufacturingEngineering,
NEDUniversityofEngineeringandTechnology.
Communications Computing Services Manufacturing Defense & Aerospace Medical Automotive
ResourcePerson
AssistantProfessor
DepartmentofIndustrialandManufacturingEngineering,
Dr.MuhammadWasif,PMP(AssistantProfessor IMD,NEDUET)
Resource Person
Qualification
2003 B.E.inMechanicalEngineeringfromNEDUniversity.
2007 M.Engg.InIndustrial&ManufacturingEngineeringfromNEDUniversity.
2013 Ph.D.inMechanicalEngineeringfromConcordiaUniversity,
Montreal(Quebec)Canada.
2016 ProjectManagementProfessional(PMP)
Experience
20042006 WorkedinAssemblyOperationsPlantofHinopak MotorsLtd.

DevelopedtheVehical InspectionDepartment(VID)onMainAssemblyLine
20082012 ResearchProjectfortheaccuratemanufacturingofHypoidGears.
2006 todate WorkedasLecturerandAsst.ProfessorinIMD,NEDUET.
AreaCoordinator&AuditorforISOManagement.
Member,BoardofReview,QualityManagementCell.
Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)
Projects
Optimizationofmillingparametersforvarioustypesoffibers
reinforcedcompositematerials(FRP)(SUPARCO,2015).
Optimalparametersforthedrillingofcarbonfiberreinforced(FRP)
compositematerial(SUPARCO,2015).
Influence&ImpactofVendorPerformanceSystemforAutomobile
SupplyChainIndustry.(PakSuzukiMotorsLimited,2014).
Optimizationofparametersfortheplasmacoatingofaerospacealloys
(PakistanAirForce PAF,2014,).
Processes/parameteroptimizationfordeepholedrillingusing
coated/uncoatedHSSdrillsonthreedifferentmaterialssuchasMS,
ALAlloy(AA2024)&Titanium.(SUPARCO,2013).
4
Projects
ReverseEngineeringofthe250ccengineofamultipurposevehicle,to
bedevelopedandmanufactureinPakistan,incollaborationwiththe
DICEFoundation,USA.(3projectsNEDUET,DICEFoundationUSA
andanentrepreneur/investor,2015).
StudythebehaviorofSpringbackofhightensileHotRolledSteel.
(PakSuzukiMotorsLimited,2014).
ProductivityincreasebyOptimizationofInvestmentCastingProcess.
(PrecisionEngineeringComplex PEC,PIA,2014).
DevelopmentofanAutomaticIdentification&DataCapture(AIDC)
systemusingRadioFrequencyIdentificationDevice(RFID)fora
Warehouse(2014).
5
Class Room Decorum
ProjectManagementclassisanopendiscussionforum,wherestudents
canaddtheirexperiencesorraisequeries.
Duringdiscussions,resourcepersonwillactasmoderator.
Punctualityoftimeisnecessarytovalidatetheattendance,elseitwillbe
markedabsent.
OneBreakwillbeallowedforMaghrebprayerandrefreshment.
Mobilephoneringtonesshouldbeonsilent.
Food,smokingandDrinksnotallowed.
Submissionofassignmentsandconductionoftestswillbeonprescribed
dates.
AssignmentsmustbesubmittedwiththeAssignmentFormuploaded
ononedrive.
6
Course Contact
Classcontacthours
Class
Day
Timings
MEM (IM)
Thursday
18:00pmto21:00pm
Consultinghours
Beforeandafterclassorbyappointment
ConsultingOffice
Room2,Groundfloor,DepartmentofIndustrial
andManufacturingEngineeringBuilding.
email
mwasif@hotmail.com
Sentyourinformation http://goo.gl/forms/JKRBxEt07h
Onceformisfilled,youwillreceivegoogle
drivelinktoaccessthelectureslides.
7
Recommended Books
Book
Author
Edition
Publishers
:StatisticalQualityControl
:DouglasC.Montgomery
:6th
:Wiley&Sons
Book
Author
Edition
Publishers
:FundamentalsofQualityControlAndImprovement
:Amitava Mitra
:2nd or3rd
:Wiley&Sons
Book
Author
Edition
Publishers
:StatisticalProcessControlAndQualityImprovement
:GeraldM.Smith
:5th
:PearsonInternational
8
Sessional Marks
Final Examination Marks 60
Sessional Marks
40
Quiz (Mid-Term)
15
Assignments
15
Class participation
Attendance
9
Course Contents
1.
ReviewofProbability&Statistics,
2.
ProbabilityDistributions,
3.
HypothesisTesting(OneTailandTwoTailTests),
4.
SamplingDistributions,
5.
QualityControl&Assurance,
6.
CausesofVariation,
7.
ControlCharts(forattributesandvariables),
8.
EWMAChartandCUSUMChart,
9.
Metrology&Gauging,
10.
GaugeCapabilityAnalysis,
11.
GaugeRepeatabilityandReproducibility,
12.
ProcessCapabilityIndices,
13.
AcceptanceSampling(forattributesandvariables).
10
Course Objectives
Develop clear understanding of the use of modern

statistical methods for quality control and improvement
To develop the knowledge of principles and the basis for

applying them in a variety of situations (mostly
engineering and management)
To understand the analysis and use to computeraided

tool for the quality control and imrpovement
11
Topic # 1
Introduction to
ResourcePerson
AssistantProfessor
DepartmentofIndustrialandManufacturing
Engineering,
Statistics and Quality
Use of statistical methods to improve

the quality of the products
How : to Monitor and Control a Process
Statistics: is the study of the Collection,

Organization, Analysis, Interpretation,
and Presentation of Quantitative data
Manufactured
goods:
such
as
automobiles, computers, and clothing,
appliances
Services such as the generation and

distribution of electrical energy, public
transportation, banking, retailing, and
health care.
14
Definition of Quality
What is quality ?
Fitness for use: conformancetospecifications (Juran)
Quality of design: various grades or levels of quality

Safe and smooth transportation but with various size, appointments,
appearance, and performance
E.g. Toyota, Lexus, Hino are different brand of Toyota

Group.
Quality of conformance: how well the product conforms to

the specifications required by the design (Crosby)
This definition does not address fitfor use by the

customer
15
Modern Definition of Quality

What is quality ?
Quality is inversely proportional to variability
A comparative study of a transmission that was manufactured in a domestic
plant and by a Japanese supplier
Warrantycostsfortransmissions
Distributionsofcritical
dimensionsfortransmissions.
16
Dimensions of Quality
17
Dimensions of Quality (Garvin 1987)

Dimension
Meaning&Example
Performance
Primary ProductCharacteristics,suchastheBRIGHTBNESSofthePicture.
(willtheproductdotheintendedjob?)
Reliability
ConsistencyofPerformanceoverTime, averagetimefortheunittofail.
(Howoftendoestheproductfail?)
Durability
Usefullife, includesRepair.
(Howlongdoestheproductlast?)
Serviceability
ResolutionofproblemsandComplaints,easeofrepair.
(How easyisittorepairtheproduct?)
Aesthetic
SensoryCharacteristics,suchasEXTERIORFINISH.
(Whatdoestheproductlooklike?)
Features
SecondaryCharacteristic,addedFeatures,suchasREMOTE CONTROL.
(Whatdoestheproductdo?)
PerceivedQuality
(Reputation)
PastPerformanceandotherIntangibles suchasbeingRanked1st.
(Whatisthereputationofthecompanyoritsproducts?)
Conformanceto
Standards
MeetingSpecificationsorIndustryStandards, Workmanship.
(Istheproductmadeexactlyasthedesignerintended?)
Response
Humantohumaninterface,suchasCourtesyofthedealer.
18
Quality improvement
It is the reduction of variability in

processes and products
Excessive variability in process performance

often results in waste.
Quality improvement is the elimination of

waste
Particularly effective in service industries,

where there may not be as many things that
can be directly measured
19
Quality Engineering Terminology
A characteristics of products that describe the user or consumer

thinks of as quality is called quality characteristics (critical
toquality (CTQ) characteristics)
Structural (Length, Weight, Strength etc.)
Sensory ( Taste, Smell, Color etc.)
Time Oriented (Warranty, Reliability, Durability etc.)
Ethical Characteristics (Honesty, Courtesy, Friendliness etc.)
20
10
Quality Characteristics fall into TWO broad classes;
Variables : Characteristic that are Measurable and are

expressed on a Numerical Scale are called Variables.
For example: Diameter, Length, Density, Resistance of Coil
Attributes:
(Countable
Characteristic)
A
Quality
Characteristic is said to an Attribute (Countable) if it is
classified as either Conforming of Nonconforming to a
stipulated Specification.
For example: Smell of Cologne, Color, Go/nogo, Pass/Fail

21
Standard or Specification: Quality characteristics are often

evaluated relative to specifications. E.g.
Inmanufacturingdiameterisshaft250.5means24.5mmto25.5mm
Inservicemaximumtimeatcheckoutcounter90seconds.
Target or nominal values: desired value for that quality

characteristic (25mm)
Lower specification limit (LSL): Smallest allowable value for a
quality characteristic (24.5mm)
Upper specification limit (USL): Largest allowable value for a
quality characteristic (25.5mm)
Non Conformity: Defect (26mm or 24.4mm)
Nonconforming Unit : Defective
Not all products containing a defect are necessarily defective
22
11
Quality of Design: (Should be Simple &

Least Expensive) It implies that the
Product or Service must be Designed to
meet at least minimally the needs of the
Consumer.
Quality of Conformance: Quality of
Conformance
implies
that
the
Manufactured Product or the Service
rendered must meet the Standards selected
in the Design phase.
QUALITY
Quality of
Conformance
Quality of
Design
Quality of
Performance
Quality of Performance: It is concerned

with how well the Product Functions or
Service performs when put to use.
23
Voice Of Customer (VoC): The voice of

the customer is the term to describe the
stated and unstated customer needs or
requirements.
Voice Of Process (VoP): It results of the
historical performance of the process (or
system). The VoP details, what the process
is capable of producing.
Concurrent engineering: a team approach
to
design,
with
specialists
in
manufacturing, quality engineering, and
other disciplines working together with the
product designer at the earliest stages of the
product design process.
24
12
Quality Circle: It is typically an informal group of people

that consists of Operators, Supervisors, Managers, and so on,
who get together to improve ways to make the product or
deliver the service.
25

QUALITYCONTROL
QualityControlmaygenerallybedefined as
asystemtomaintainadesiredlevelina
ProductorService.
(Amitva Mitra)
ASystemthatisusedtomaintainadesired
levelofQualityinaProductorService.
(Amitva Mitra)
QCistheOperationalTechniques&
Activities whichsustainaQualityof
ProductorServicethatwillgivenneeds.
(WilliamJ.Kalorik)
QUALITYASSURANCE
AllthosePlannedorSystematicActions
necessarytoprovideconfidencesthata
ProductorServiceSatisfygivenneeds.
(AmitvaMitra)
QUALITYENGINEERING
QualityEngineeringistheSetofOperational,
Managerial&EngineeringActivitiesthat
acompanyusestoensurethataQuality
CharacteristicsofaProductareatthe
NominalorRequiredlevel.
(AmitvaMitra)
QUALITYPLANNING
IsaStrategicActivity,anditisjustanvitaltoanorganizationslongtermbusinesssuccessas
theproductdevelopmentPlan,theFinancialPlan,theMarketingPlan,andthePlanfor
utilizationofHumanResources.
(DouglasC.Montgomery)
26
13
27
History of Quality Improvement
28
14
Statistical Methods for Quality Control and

Improvement
Process is a series of activities that takes an Input, adds value to it and produces an
Output for a Customer
Controllable Inputs:
Temperature, Pressure
X1, X2, . . . . . . , Xn
MeasurementEvaluation
Monitoring&Control
Input
Process
Raw Material,
Components,
Sub-assemblies,
and/or
Information
Y=Quality
Characteristics
(CTQs)
Output Product
Z1, Z2, . . . . . . , Zn
Uncontrollable Inputs:
Environmental Factors,
Properties of Raw Material
provided by External Customer
[ProductionProcessInputsandOutputs]
29
Statistical Methods
Statistical process control (SPC):
Control charts, plus other problemsolving tools
Useful in monitoring processes, reducing variability

through elimination of assignable causes
Online technique
Input
Discovering the key factors that influence process

performance
Process optimization
Offline technique
Output
Search for input that vary

the output
Designed experiments (DOE)
Process
Input
Process
Output
Input is optimized for

desired output
Acceptance Sampling
It is the Inspection and classification of a sample

selected at random from a larger batch or lot
ultimate decision about disposition of the lot,
occurs at two points: incoming raw material,
production.
of units
and the
usually
or final
Input
scrap
Process
Output
Input is sampled to
analyzed for desired output
30
15
Statistical Methods
31
Quality Philosophy & Management Strategies

Walter A. Shewhart (1891-1967) : (Some times referred as Father of SQC)
worked at the Hawthorne Plant of Western Electric, where he developed
(1924) and used Control Charts.
He describes the basic Principles of SQC in his book Economic Control of
Quality of Manufactured Product (1931).
He was the first honorary member of ASQ.
W. Edward Deming:
Developed a list of 14 Points.
Deming Cycle (PDSA Cycle)
Deming's Seven Deadly Diseases of Management
Joseph M. Juran (1904-2008):

Developed the Juran Trilogy.
Deming and Juran worked in both the US and Japan to help businesses
to understand the importance of Continuous Improvement.
32
16
Quality Philosophy & Management Strategies

Philip B. Crosby:
Originated the Zero Defect Concept.
Was an ASQ honorary member and Past President.
Armand V. Feigenbaum :
Originated the concept of Total Quality Control.
He is an ASQ honorary member and served as ASQ President for Two
consecutive terms.
Kaoru Ishikawa:
Developed Cause and Effect Diagram.
He worked with Deming through the Union of Japanese Scientists and
Engineers (JUSE)
Genichi Taguchi:
Taught that any departure from Nominal or Target value for a characteristic
represents a Loss to Society.

He is also popularized the use Fractional Factorial Experiments.
33
Demings Deadly Diseases

1.
Lack of constancy of purpose
2.
Emphasis on shortterm profits
3.
Performance evaluation, merit rating, annual

reviews
4.
Mobility of management
5.
Running a company on visible figures alone
6.
Excessive medical costs for employee health

care
7.
Excessive costs of warrantees

34
17
Shewart Cycle (PDCA cycle)
35
Shewart Cycle (PDCA cycle)

Other Short Topics just define them:
TQM
(Total QualityManagement)
Deming/Juran
Valueengineering
Zerodefect philosphy
QualitySystems&Standards
ISO
Genericstandard forQuality
systems
SixSigma
Motorola
Invariability
Movingmean
36
18
Quality Systems and Standards
37
Quality Systems and Standards
The ISO certification process focuses heavily on quality

assurance, without sufficient weight given to quality planning and
quality control and improvement
38
19
Six Sigma
Use of statistics & other analytical tools has grown steadily for
over 80 years
Statistical quality control (origins in 1920, explosive growth

during WW II, 1950s)
Operations research (1940s)
FDA, EPA in the 1970s
TQM (Total Quality Management) movement in the 1980s
Reengineering of business processes (late 1980s)
SixSigma (origins at Motorola in 1987, expanded impact

during 1990s to present)
39
Six Sigma
A process is an organized sequence of activities that produces an

output that adds value to the organization
All work is performed in (interconnected) processes
Easy to see in some situations (manufacturing)
Harder in others
Any process can be improved
An organized approach to improvement is necessary
The process focus is essential to Six Sigma
40
20
Six Sigma
41
Six Sigma Focus
Initially in manufacturing
Commercial applications
Banking
Finance
Public sector
Services
DFSS Design for Six Sigma
Only so much improvement can be wrung out of an existing

system
New process design
New product design (engineering)
42
21
Six Sigma Focus
Initially in manufacturing
Commercial applications
Banking
Finance
Public sector
Services
DFSS Design for Six Sigma
Only so much improvement can be wrung out of an existing

system
New process design
New product design (engineering)
43
Six Sigma
A disciplined and analytical approach to process and product

improvement
Specialized roles for people; Champions, Master Black belts, Black
Belts, Green Belts
Topdown driven (Champions from each business)
BBs and MBBs have responsibility (project definition, leadership,
training/mentoring, team facilitation)
Involves a fivestep process (DMAIC) :
Define
Measure
Analyze
Improve
Control
44
22
Lean Systems
Focuses on elimination of waste
Long cycle times
Long queues inprocess inventory
Inadequate throughput
Rework
Nonvalueadded work activities
Makes use of many of the tools of operations research and

industrial engineering
45
Quality Cost
46
23
Managing Quality Cost
47
Managing Quality Cost
48
24

Topic-1 Introduction To SQC

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LectureNotesofStatisticalQualityControl(IM511)

Statistical Quality Control

Communications Computing Services Manufacturing Defense & Aerospace Medical Automotive

20042006 WorkedinAssemblyOperationsPlantofHinopak MotorsLtd.

2006 todate WorkedasLecturerandAsst.ProfessorinIMD,NEDUET.

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Class Room Decorum

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Develop clear understanding of the use of modern

To develop the knowledge of principles and the basis for

To understand the analysis and use to computeraided

Statistics and Quality

Statistical Quality Control

Use of statistical methods to improve

How : to Monitor and Control a Process

Statistics: is the study of the Collection,

Services such as the generation and

Quality of design: various grades or levels of quality

E.g. Toyota, Lexus, Hino are different brand of Toyota

Quality of conformance: how well the product conforms to

This definition does not address fitfor use by the

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Modern Definition of Quality

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Dimensions of Quality (Garvin 1987)

It is the reduction of variability in

Excessive variability in process performance

Quality improvement is the elimination of

Particularly effective in service industries,

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Quality Engineering Terminology

A characteristics of products that describe the user or consumer

Structural (Length, Weight, Strength etc.)

Sensory ( Taste, Smell, Color etc.)

Time Oriented (Warranty, Reliability, Durability etc.)

Ethical Characteristics (Honesty, Courtesy, Friendliness etc.)

Quality Engineering Terminology

Quality Characteristics fall into TWO broad classes;

Variables : Characteristic that are Measurable and are

For example: Diameter, Length, Density, Resistance of Coil

For example: Smell of Cologne, Color, Go/nogo, Pass/Fail

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Quality Engineering Terminology

Standard or Specification: Quality characteristics are often

Target or nominal values: desired value for that quality

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Quality Engineering Terminology

Quality of Design: (Should be Simple &

Quality of Performance: It is concerned

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Quality Engineering Terminology

Voice Of Customer (VoC): The voice of

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Quality Engineering Terminology

Quality Circle: It is typically an informal group of people

Quality Engineering Terminology

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)

Quality Engineering Terminology

History of Quality Improvement

Statistical Methods for Quality Control and

Dr.MuhammadWasif,PMP Asst.Professor(IMD NEDUET)