BE 300 MANUFACTURING

PROCESS LABORATORY
REFERENCE
General Instruction
Students should pass safety test
Students should be familiar with equipments
and machines before to use them
We have a long tradition to make a
gyroscope.
We will measure the length and diameter of
the screws as well as the diameter of washers
to simulate a statistical process control
Rules
Students must submit the laboratory
form to Mr. James Altop before they
start the work at the laboratory.
The collected Laboratory forms will be
the basis of your grade for attendance
and achievements. Any safety violation
will heavily affect your grade.

ME 300L MANUFACTURING PROCESS LAB
ATTENDANCE SHEET

This sheet will be a basis for your final grade. Please turn in this sheet every time you
visit the laboratory, otherwise it will be recorded as absences. Please submit to Mr.
James Altop before you leave.

Date____________________
Your Name__________________________Signature________________
Time in ___________________ Time out ____________________
Team members name that are working with you today. Identify who are missing today.



Describe the task you planned to do today




What did you achieve today? Are there any remarks and suggestions?




Official Notes (signed by Mr. James altop)


Observed safety rules? Poor Moderate Good
Behaved well? Followed instructions? Poor
Moderate Good
Cleaned and reorganized after work? Poor
moderate Good
Worked efficiently? Poor moderate Good
Work quality Poor moderate Good
Any remarks?



How to Write the Report
Students must write the laboratory
reports in a professional way. Please
think that the reader of your report is a
non-engineering person, maybe your
boss in marketing department, or a
lawyer investigating an accident.
Due Date of the Laboratory Reports
The statistical process control report is
due by July 26.
The report for the manufacturing of the
gyroscope is due by August 2.
Remarks on Notebook
The lab notebook starts with the introduction
of elementary statistics. I will teach you later.
Your laboratory reports must contain graphs,
tables, and theoretical backgrounds.
The first lab on the notebook is the measuring
Brinell hardness before and after rolling
process and heat treatments. I believe you did
a Brinell test at GE 206 Lab. I will skip this
test.
Remarks on Notebook, Continued
The second lab is about quality and process
control/measurements. We will do this lab.
Your report must be a fully written report
(not a laboratory sheet, which is nothing but
a raw data). Please write the followings;
introduction, scope of the work, theoretical
background, your results (not raw data, but
processed data; attach raw data as a
reference), analysis, conclusion, suggestions,
references.
Remarks on Notebook, Continued
The next one is about Hardenability
(Jominy test). We will skip this. During
class, I will cover this.
The mechanical properties test , I
believe, was done at GE 206 Lab.
We will do the Gyroscope project.
No welding project for the summer
semester

Remarks on Notebook, Continued
The forging and sheet metal process
will be skipped. I recommend you a
field trip to see the process.
CNC machine; we will not do this as the
project. But I believe you will learn to
use it before you graduate.
Safety
1. Report any injury to Mr. James Altop or to Dr.
Jung
2. When in doubt about the use of machines,
equipment or instrumentation, check with Mr.
Altop. Many accidents are caused by
improper use
3. Know where your first aid equipment is
located.
4. Know where your fire extinguishers are
located and how to use them.
Safety; cont
5. Never work alone in the laboratory.
6. Emergency number is 911.
7. Wear your safety glasses or eye shields
when you are producing metal chips,
using machine tools or hand tools, or are
in the vicinity of such a hazard.
8. Report all broken, damaged, or missing
tools.

Safety; cont
9. Remove chuck keys from chucks and
other tools from machines before starting
them. Never leave a machine unattended
with a chuck key in the chuck.
10.Never touch or try to remove chips from
your work or machine while it is running.
Never handle the chips with your bare
hands. Use a brush or paper towel.
11. Never leave a running machine
unattended.
Safety; cont
12.Do not wear neckties or other loose
fitting clothes that could become
entangled in a running machine.
13.Always clean your machine and working
area when you are finished.
14.If a classmate is in danger by improper
use of equipment, be a buddy, and
provide assistance.
Statistics
Dealing With Uncertainty
Objectives
Describe the difference between a sample and a
population
Learn to use descriptive statistics (data sorting,
central tendency, etc.)
Learn how to prepare and interpret histograms
State what is meant by normal distribution and
standard normal distribution.
Use Z-tables to compute probability.
Statistics

There are lies, d#$& lies,
and then theres
statistics.
Mark Twain

Statistics is...
a standard method for...
- collecting, organizing, summarizing,
presenting, and analyzing data
- drawing conclusions
- making decisions based upon the
analyses of these data.
used extensively by engineers (e.g.,
quality control)
Populations and Samples
Population - complete set of all of the
possible instances of a particular object
e.g., the entire class
Sample - subset of the population
e.g., a team
We use samples to draw conclusions
about the parent population.
Why use samples?
The population may be large
all people on earth, all stars in the sky.
The population may be dangerous to observe
automobile wrecks, explosions, etc.
The population may be difficult to measure
subatomic particles.
Measurement may destroy sample
bolt strength
Measurements
Measurements are frequently made in
engineering and science. These
measurements are made to quantify
characteristics of the system being studied.
If the measurement can be reduced to a
single value that we are 100% certain is the
true value, we do not need statistical methods
For most measurements, we are not 100%
certain; thus, statistical techniques need to be
used.

Team Exercise: Sample Bias
To three significant figures, estimate
the average age of the class based
upon your team.

When would a team not be a
representative sample of the class?
Measures of Central Tendency
If you wish to describe a population (or a
sample) with a single number, what do you
use?

Mean - the arithmetic average
Mode - most likely (most common) value.
Median - middle of the data set.
What is the Mean?
The mean is the sum of all data values
divided by the number of values.
Sample Mean
Where:
is the sample mean
x
i
are the data points
n is the sample size

=
=
n
i
i
x
n
x
1
1
x
Population Mean
Where:
is the population mean
x
i
are the data points
N is the total number of observations in the
population

=
=
N
i
i
x
N
1
1

What is the Mode?

mode - the value that occurs the most
often in discrete data (or data that have
been grouped into discrete intervals)

Example, students in this class are
most likely to get a grade of B.
Mode continued
Example of a grade distribution with
mean C, mode B

0
5
10
15
20
25
F D C B A
What is the Median?
Median - for sorted data, the median is
the middle value (for an odd number of
points) or the average of the two middle
values (for an even number of points).
useful to characterize data sets with a
few extreme values that would distort
the mean (e.g., house price,family
incomes).
What Is the Range?
Range - the difference between the
lowest and highest values in the set.
Example, driving time to Portland is 2
hours +/- 15 minutes. Therefore...
Minimum = 105 min
Maximum = 135 minutes
Range = 30 minutes
Standard Deviation


Gives a unique and unbiased
estimate of the scatter in the data.
Standard Deviation
Population



Sample
2
1
) (
1
o

=
=
N
i
i
x
N
2
1
) (
) 1 (
1
x x
n
s
n
i
i
=

=
Deviation
Variance = o
2

Variance = s
2

The Subtle Difference
Between o and s
N versus n-1
n-1 is needed to get a better estimate of
the population o from the sample s.

Note: for large n, the difference is trivial.
A Valuable Tool
Gauss invented standard deviation circa
1700 to explain the error observed in
measured star positions.
Today it is used in everything from
quality control to measuring financial
risk.
Team Exercise
In your teams bag of M&M candies,
count
the number of candies for each color
the total number of candies in the bag
When you are done counting, have a
representative from your team enter
your data on the board
Using Excel or calculators, enter the
data gathered by the entire class
More
Team Exercise (cont)
For each color, and the total number of
candies, determine the following:

maximum mode
minimum median
range standard deviation
mean variance




Individual Exercise:
Histograms
Flip a coin EXACTLY ten times. Count the
number of heads YOU get.
Report your result to the instructor who will
post all the results on the board
Open Excel
Using the data from the entire class, create
bar graphs showing the number of
classmates who get one head, two heads,
three heads, etc.
Data Distributions
The shape of the data is described by
its frequency histogram.
Data that behaves normally exhibit a
bell-shaped curve, or the normal
distribution.
Gauss found that star position errors
tended to follow a normal distribution.

The Normal Distribution
The normal distribution is sometimes
called the Gauss curve.
( )
2
2
/
2
1
2
1
RF
o
t o

=
x
e
mean
x
RF
Relative
Frequency
Standard Normal Distribution
Define:

Then
( ) o / = x z
t 2
RF
2
2
1
z
e

=
0.0
0.1
0.2
0.3
0.4
0.5
-4.0 -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0 4.0
Area = 1.00
z
Some handy things to know.
50% of the area lies on each side of the
mid-point for any normal curve.
A standard normal distribution (SND)
has a total area of 1.00.
z-Tables show the area under the
standard normal distribution, and can
be used to find the area between any
two points on the z-axis.
The area under the probability density
function equals 1 meaning that the probability
that x has a value between the lower and
upper limit is certain.
Therefore, the shaded area under the curve
defines a probability of 0.6827 that x has a
value between 2o and + 2o
Mathematically, this probability is defined as
}
+

=
o
o
o o
2
2
) ( ] 2 2 [ dx x f x P
There are a few situations where it is
impractical to make measurements on all
items in the population; therefore, samples
are used.
Again, the measurements made on the
sample are random variables; however, new
definitions and techniques are needed to
condense sample measurements to obtain
meaningful information regarding the
population from which the sample was
obtained.
Statistical techniques are used for these
purposes
Summary Table
Sample
Statistics
Population
Parameters
Mean
Variance S
2
o
2
Standard
deviation
S=(S
2
)
1/2
o=( o
2
)
1/2
x
Confidence Intervals
Confidence intervals are calculated using
sample data and define a probable range for
a population parameter at a given confidence
level.
For example, a 95% confidence interval will
define and upper and lower limit for a
parameter and implies that we are 95%
certain based on the sample used that the
parameter is between these limits. We will
only consider confidence intervals for the
population mean,
Large Sample Method
When the sample is large enough we can
assume that s
x
2
= o
2
; thus, three common
confidence intervals are:

99%

95%

90%
|
.
|

\
|

n
s
x
x
58 . 2
|
.
|

\
|

n
s
x
x
96 . 1
|
.
|

\
|

n
s
x
x
64 . 1

Small Sample Method
For small samples, the sample variance
has not stabilized and the assumption,
s
x
2
= o
2
cannot be made. The
confidence interval now is defined as:
|
.
|

\
|

n
s
t x
x
n t n t
2 12.7 11 2.33
3 4.3 12 2.20
4 3.18 13 2.18
5 2.78 14 2.16
6 2.57 15 2.14
7 2.45 16 2.13
8 2.36 17 2.12
9 2.31 18 2.11
10 2.26 19 2.10
20 2.09
95% confidence interval
Using Confidence Intervals
When conducting experiments, it is best to
replicate (repeat) tests or measurements of
values on a test part. The sequence of values
that represent the characteristic of interest
are used to make a decision regarding the
population that the sequence of values (the
sample) are supposed to represent.
The average value of the characteristic is the
most natural way to condense these sample
values and it is hoped that this average is
close to the true average for the population.
The confidence interval is used to
provide a measure of how close. The
smaller the confidence interval, the
closer the sample mean is to the
population mean.
Another way to use the confidence
interval is to make comparisons among
multiple samples.
Using Confidence Intervals
Let' say you have two samples consisting of
measurements of the same characteristics
such as a material's hardness. One sample
was taken from a batch of material that was
heat treated at one temperature and the
second sample from a batch heat treated at a
different temperature
The average sample hardness for these
batches differ. Does this mean the
temperature difference has affected
hardness? Not necessarily.
Using Confidence Intervals
A confidence interval for these average
values should be computed. If the
lower bound of one confidence interval
is greater than the upper bound of the
second confidence interval, we can be
more confident that the temperature
has affected hardness.

Using Confidence Intervals
STATISTICAL QUALITY
CONTROL
See Quality Control Chapter
Using Z Tables
Question: Find the area between z= -1.0
and z= 2.0
From table, for z = 1.0, area = 0.3413
By symmetry, for z = -1.0, area = 0.3413
From table, for z= 2.0, area = 0.4772
Total area = 0.3413 + 0.4772 = 0.8185

Tails area = 1.0 - 0.8185 = 0.1815
Quick and Dirty Estimates of
and o
~ (lowest + 4*mode + highest)/6
For a standard normal curve, 99.7% of
the area is contained within 3 o from
the mean.
Define highest = + 3 o
Define lowest = 3 o
Therefore, o ~ (highest - lowest)/6

Example:
Drive time to Everette
Lowest = 1 h
Most likely = 2 h
Highest = 4 h (including a flat tire, etc.)
= (1+4*2+4)/6 = 2.16 (2 h 12 min)
o = (4 - 1)/6= 0.5 h
This technique (Delphi) was used to
plan the moon flights.
Review
Central tendency
mean
mode
median
Scatter
range
variance
standard deviation
Normal Distribution

Data Analysis in Excel
Analysis of Uncertainty
Learning Objectives
Learn to use statistical Excel functions:
average, median, min, max, stdev, var, varp,
standardize, normdist, norminv, normsinv
General Excel Behavior

- Analyzes the range of cells you
specify
- Skips blank cells
Mean
Excel

=AVERAGE(cellrange)
=AVERAGE(B72:B81)
Example:

=
=
n
i
i
x
n
x
1
1

=
=
N
i
i
x
N
1
1

Sample Population
Mode
Value that occurs most often in
discretized data

Excel Example:
=MODE(cellrange) =MODE(B2:B81)

If tie, reports first value in list

Median
The middle value in sorted data

Excel
=MEDIAN(cellrange)
=MEDIAN(D2:D81)
Example:
Note: When using this command,
there is no need to sort the data first.
Maximum, Minimum, and
Range
Excel Example:
=MIN(cellrange) =MIN(D2:D81)
=MAX(cellrange) =MAX(D2:D81)

There is no explicit command to find the range.
However, it can be easily calculated.

= MAX(D2:D81) - MIN(D2:D81)

Standard Deviation and
Variance
Population Sample




Excel
=STDEVP(cellrange)
=STDEV(cellrange)
=VARP(cellrange) =VAR(cellrange)

2
1
) (
1
o

=
=
N
i
i
x
N
2
1
) (
) 1 (
1
x x
n
s
n
i
i
=

=
Variance = o
2
Variance = s
2

Example - Exam Grades
Data set: grades.xls
78 students, 1 did not take exam
Verify the following:
Mean is 79.41
Mode is 79 - occurs 6 times
Median is 79.5
median close to mean suggests no major outliers
Remember, student who did not take exam is not
included in data
More
Example Cont.
Verify
max is 99
min is 60
Range is 99-60 = 39
Population variance is 60.7
Population std. dev. is 7.79
Team Exercise - 15 min
Collect ages (in months) of team
members and members of teams
around you (at least 15 values)
Enter as a column in Excel
Compute mean, mode, median, max,
min, range, sample variance and std.
dev. using Excel commands
Z-transform
Excel

=STANDARDIZE(x,mean,stddev)

Example:

=STANDARDIZE(85,75,10) gives 1.0
( ) o / = x z
Standard Normal Cumulative
Distribution
Excel Example:
=NORMSDIST(z) =NORMSDIST(1.0)
=0.8413

0.0
0.1
0.2
0.3
0.4
0.5
-4.0 -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0 4.0
area from minus
infinity to z

NOT

0 to z, like Z-table
Normal Data in Excel
To avoid Z transform, use:

=NORMDIST(x,mean,stddev,true)

Example

=NORMDIST(85,75,10,true)
= 0.8413

Exam Grade Histogram
0
5
10
15
20
25
50 55 60 65 70 75 80 85 90 95 100
Score Bins
F
r
e
q
u
e
n
c
y
Actual Scores
Normal Approx
Excel Example
Normal distribution with =5, o=0.2
Find area from 4.8 to 5.4

Solution 1:
=STANDARDIZE(4.8,5,0.2) Gives -1
=STANDARDIZE(5.4,5,0.2) Gives 2
=NORMSDIST(2)-NORMSDIST(-1) = 0.8186
Solution 2:
=NORMDIST(5.4,5,0.2,TRUE)-
NORMDIST(4.8,5,0.2,TRUE) = 0.8186
Inverse Problem
Given , o and probability, find x
=NORMINV(prob,mean,stddev)

Given probability, find z
=NORMSINV(prob)

Note: The probability is the area under the
curve from minus infinity to x (or z)
Inverse Problem:
Example 1
A batch of bolts have length =5.00 mm, o=0.20
mm.
99% of the bolts are shorter than what length?

Solution 1:
=NORMINV(0.99,5,0.2) gives 5.47 mm

Solution 2:
=NORMSINV(0.99) = 2.33
5.00+0.20*2.33 = 5.47 mm
Inverse Problem:
Example 2
A batch of bolts have length =5.00 mm, o=0.20
mm. The bolt length is specified as 5.00 mm
tolerance. What is the value of the tolerance
such that 99% of the bolts are encompassed?
Solution:
=NORMINV(0.995,5,0.2) = 5.52 mm
=NORMINV(0.005,5,0.2) = 4.48 mm
Tolerance = 5.52 - 5.00 = 0.52 mm

Note: It is symmetrical; therefore 0.5% on either side
Bolt Specification
0
0.5
1
1.5
2
2.5
4 4.5 5 5.5 6
Length
P
D
F
99% Area
Tail Tail
Team Exercise
The clock frequency of a batch of Intel
microprocessors was measured to be a normal
distribution with =475 MHz, o=50 MHz.
What fraction of processors can be sold in each
category?
>600 MHz 400 - 450 MHz
550 - 600 MHz 350 - 400 MHz
500 - 550 MHz < 350 MHz
450 - 500 MHz



Think-Pair-Share
In the next 1 minute, as an individual
list three specific things that you dont understand
about todays topic
Now take 2 minutes
to merge your list with the person sitting next to you
AND add 1 new item to the list
In the next 5 minutes
share the results with the other half of your team,
delete questions that you can answer for each
other, AND prioritize the remaining questions your
list