MENG 342-01 Quality and Process Control Spring 2012 LEC UW 11:30-12:45 C108 / Jameel LAB 81 U 3:30-6:20, QC Lab

LAB 82 W 3:30-6:20, QC Lab LAB 83 R 3:30-6:20, QC Lab

Prof. Hatem Elayat SSE 2029, Phone: 2615-3078 Office Hours: UW, 10:00-11:00 pm or by appointment Email: helayat@aucegypt.edu TA: Irene Fahim, SSE 2004 Office Hrs: UW, 10:00-11:00 am Email: rico4000@aucegypt.edu

SYLLABUS Course Description Fundamentals of statistical quality control; control charts for variables and attributes; process capability analysis; sampling plans and techniques; introduction to design of experiments. Two class periods and one three hours lab period. Prerequisite ENGR MATH 317. (3 cr.) Course Objectives This course is an introduction to statistical-based techniques for monitoring and improving the quality of products and processes. The student will: Learn to apply control charts to monitor the quality characteristics of a product or process Learn techniques for assessing how capable a process is of achieving given design specifications Design and analyze experiments for improving a manufacturing process Textbook Montgomery, Douglas C., Statistical Quality Control A Modern Introduction, Six Edition, 2009, John Wiley & sons, ISBN: 978-0470-23397-9 Course Outcomes

With the successful completion of this course you will be able to: 1. Apply statistical theory to product and process measurements. 2. Apply control charts to monitor the quality characteristics of a product or process. 3. Assess how capable a process is of achieving given design specifications. 4. Utilize existing software to develop control charts and monitor the quality of a process. 5. Apply factorial and fractional factorial experiments for process design. Course Website: Blackboard Lectures, handouts, assignments, announcements and other information will be available on the course website on Blackboard. The following modules are included on Blackboard: 1. 2. 3. 4. 5. 6. Course outline Lectures Handouts Assignments Labs Grades

Email Policy Please include in the Subject line the course code MENG 342 and a concise and clear statement of purpose; otherwise it may be deleted, along with spam messages and messages potentially containing viruses. Lectures I will use overheads during lectures and will put copies on Blackboard. Other details will be given on the board. You should read the material before lecture so that you have some idea of what will be discussed even if you don't understand everything. Please ask questions as I go along. Most of our time will be spent covering more difficult material rather than things you can understand easily. Class lectures definitely will not replace reading the textbook. Lab experiments, as well as handouts, will be posted on Blackboard. Course Requirement

The requirement will consist of two mid-term examinations and a final examination. The dates for these exams are listed below. Unannounced quizzes will be given to students at regular intervals. In addition, seven assignments are posted on Blackboard and students are expected to complete the assignments and turn them in on the due dates. No late assignments will be accepted, and no makeup (tests, quizzes) will be allowed. Nine experiments will be carried out in the Lab. The students are expected to complete the experiments and write a report describing the work done. Students are required to turn in the reports on the due date. Exams The first midterm examination covers topics discussed in week 1-5. The second midterm examination covers topics discussed in week 6-10. The final examination is comprehensive. Students will be tested on material covered in class & Lab. All exams will be closed book and notes. If you miss an exam because of illness, notify the department office (2615-3063, 2615-3153) immediately (same day) & provide a medical note from AUC Medical Clinic before a make-up exam will be allowed. Failure to do so will earn you zero credit on the exam. If you miss an exam because of travel or other circumstances, prior instructor written approval is required one week before the exam. Tentative Dates Midterm Exam I will be given on Sunday March 4, 2012. Midterm Exam II will be given on Wednesday April 18, 2012. Final Exam will be given during Final week. Quizzes Unannounced quizzes will be given at regular intervals covering recent material discussed in class & Lab. No make up allowed if you miss a quiz. If you miss a class because of illness, notify the department office (2615-3063, 26153153) immediately (same day). If a quiz is given that day, you will be given the quiz at a later date provided: 1. You notified the department about your illness immediately, 2. You provide a medical note from AUC Medical Clinic. Missing class, because of travel or engagement in AUC activities requires prior instructor written approval one week before that date.

Assignments Assignments are posted on Blackboard. Assignments must be turned in on the due date. Assignments turned in by students after the due date will not receive any credit. The assignment should show in detail the solution steps and the computation. Final answers should be circled. When computers are used, computer printouts should be attached to the paper turned in. Assignment 1 2 3 4 5 6 7 Lab A. Students are divided into groups of 3-4 where they perform experiments, listed below, in the QC lab, and they are expected to use some of the tools learned in this course. After the experiment is completed, students will use Excel or Minitab to perform the analysis. A report must be prepared for each experiment, it must be type written with a maximum of three double-spaced pages plus appendices, charts and graphs. No special cover required. Title sheet stapled to the report is recommended. The report will be graded for writing style as well as analysis, and conclusions. The outline to be followed is: 1 - Introduction 2 - Equipment used 3 - Analysis 4 Conclusions B. The experiments performed in the lab will consist of the following: 1. Descriptive statistics 2. Normal Probability Plots & goodness of fit test 3. Calibration of measuring instruments using Inverse Regression Analysis 4. Confidence interval & testing of hypothesis Tentative Due Date February 12, 2012 February 26, 2012 March 14, 2012 March 28, 2012 April 22, 2012 May 2, 2012 May 16, 2012

5. Control chart for variables 6. Control chart for attributes 7. Process Capability Analysis, R&R Experiment 8. Other control charts 9. Design of Experiments C. Students who dont attend the Lab or are late (after 3:45 PM) will receive zero credit for the experiment. D. To enhance the students understanding of basic statistical concepts, students will use Rice Virtual Lab in Statistics to perform simulations using java applets: http://onlinestatbook.com/rvls.html http://onlinestatbook.com/stat_sim/index.html Use of Computers We will use Microsoft Excel and Minitab to assist in processing and analyzing data for all Lab experiments, and some class assignments. The students can use their personal computers or other computers to which they have access. In addition to using computers, students should have a good engineering calculator (TI 83 or TI 89) to use for some class assignments and quizzes. Class Participation The student is expected to read the material to be discussed before the class meeting. Several handouts will be distributed in class to supplement the textbook. These handouts will be discussed in class. Each student is responsible for the material discussed and the instructions given in class even if he or she is absent. Always bring your textbook and calculator to class in addition to any handouts previously given. Active student participation in class discussions is encouraged. Come to class prepared by reading the material assigned and solving homework problems. Grading Assignments Quizzes Lab Experiments Midterm 1 Midterm 2 Final Exam 10 % 10 % 10 % 20 % 20 % 30 %

MENG 342 is graded on a curve. Academic Dishonesty Academic dishonesty is not tolerated at AUC and is subject to academic discipline ranging from a mark of zero on the exam or assignment/quiz to dismissal from the University. Academic Regulations Class policy regarding adds, drops, incomplete, absences, cheating, etc. will be in accordance with the university rules and regulations. Students will turn their cell phones off or put them on vibrate mode while in class. They will not answer their phones in class or sent text messages. Course Calendar week 1 Topics Introduction - History and evolution of QC - Statistical Methods for QC - TQM Review Theory of Probability & Statistics - Descriptive statistics - Describing variation - Important discrete distributions - Important continuous distributions - Sampling distributions - Estimation of process parameters - Hypothesis testing on process parameters

1, 2, 3

Methods and Philosophy of Statistical Process Control SPC - Statistical basis of the control chart

- The Magnificent Seven 4, 5 Control Chart for Variables - x bar and R control chart - x bar and S control chart - S2 control chart - Control charts for individual measurements MIDTERM EXAMINATION 1

6, 7, 8

Control Chart for Attributes - Control Chart for Fraction Non Conforming - Control Chart for Nonconformoties Process Capability Analysis - Process capability analysis using a histogram - PCR - Process capability analysis using a control chart - Gage and measurement system capability studies MIDTERM EXAMINATION 2 - Cumulative Sum and Exponentially Weighted Moving Average Control Charts

9, 10

11 11, 12

13, 14, 15

Factorial & Fractional Factorial Experiments for process design and improvement FINAL EXAM (during final week)

Important Dates January - This class begins Sunday January 29, 2012 February - Deadline for late registration, drop/add, tuition & fee payment, February 2, 2012 March

- Census Day, March 1, 2012 - Taba Liberation Day (H), March 19, 2012 April - International Day, April 3, 2012 (classes will be held until 12:45 pm & resumed at 4:30 pm) - Spring break (H), March 8 16, 2012 - Sinai Liberation Day (H), April 25, 2012 - Last day to drop course without WP WF grades, Thursday, April 26, 2012 May - Labor Day (H), May 1, 2012 - Last day of regular classes, May 17, 2012 - Final Exams, May 19 24, 2012