First Course in Quality Engineering : Integrating Statistical and Management Methods of Quality

by Krishnamoorthi, KS

• ISBN13: 9780131472013
• ISBN10: 0131472011
• Format: Paperback
• Copyright: 2006-01-01
• Publisher: Pearson College Div

Summary

This volume contains virtually all the information an engineer would need to function as a quality engineer. The author covers management methods and statistical methods of quality in an integrative manner unlike other books on the subject, which focus primarily on one of the two areas of quality. Illustrates the use of quality methods with many real world examples drawn from the authorrs"s consulting work. Helps students understand and solve real problems with mini projects throughout. Uses a reader-friendly writing style that makes material more approachable and encourages self-study. Covers the must-know fundamentals of probability and statistics in one chapter (Chapter 2). Makes extensive use of computer software to illustrate the use of computer in solving quality problems. A useful reference for engineers and technical personnel in industry wanting to learn the tools of quality; also for candidates preparing for the exams to qualify as a certified quality engineer (CQE) of the Am. Soc. Of Quality.

Table of Contents

Preface	p. xiii
Introduction to Quality	p. 1
A Historical Overview	p. 1
A Note About "Quality Engineering"	p. 5
Defining Quality	p. 7
Product Quality vs. Service Quality	p. 8
The Total Quality System	p. 9
Total Quality Management	p. 11
Economics of Quality	p. 12
Quality, Productivity, and Competitive Position	p. 13
Quality Costs	p. 14
A Case Study in Quality Costs	p. 27
Success Stories	p. 32
Cadillac Motor Car Company (Winner of the 1990 MBNQA)	p. 32
Boeing Airlift and Tanker Programs (Winner of the 1998 MBNQA)	p. 34
Exercises	p. 37
Mini-Project 1.1	p. 40
Mini-Project 1.2	p. 41
References	p. 42
Statistics for Quality	p. 43
Variability in Populations	p. 43
Some Definitions	p. 44
Empirical Methods for Describing Populations	p. 46
The Frequency Distribution	p. 46
The Histogram	p. 47
The Cumulative Frequency Distribution	p. 48
Numerical Methods for Describing Populations	p. 52
Calculating the Average and Standard Deviation	p. 53
Other Graphical Methods	p. 54
Stem-and-Leaf Diagram	p. 54
Box-and-Whisker Plot	p. 55
Other Numerical Measures	p. 56
Measures of Location	p. 56
Measures of Dispersion	p. 56
Exercise in Empirical Methods	p. 57
Mathematical Models for Describing Populations	p. 59
Probability	p. 59
Definition of Probability	p. 60
Computing the Probability of an Event	p. 60
Theorems on Probability	p. 63
Counting the Sample Points in a Sample Space	p. 70
Exercises in Probability	p. 73
Probability Distributions	p. 75
Random Variable	p. 75
Probability Mass Function	p. 76
Probability Density Function	p. 78
The Cumulative Distribution Function	p. 79
The Mean and Variance of a Distribution	p. 80
Some Important Probability Distributions	p. 82
The Binomial Distribution	p. 83
The Poisson Distribution	p. 85
The Normal Distribution	p. 86
Distribution of the Sample Average X	p. 93
The Central Limit Theorem	p. 94
Exercise in Probability Distributions	p. 95
Inference of Population Quality from a Sample	p. 96
Definitions	p. 96
Confidence Intervals	p. 98
CI for the [mu] of a Normal Population When [sigma] Is Known	p. 98
Interpretation of CI	p. 99
CI for [mu] When [sigma] Is Not Known	p. 99
CI for [sigma superscript 2] of a Normal Population	p. 100
Hypothesis Testing	p. 102
Test Concerning the Mean [mu] of a Normal Population When [sigma] Is Known	p. 103
Why Place the Claim Made About a Parameter in H[subscript 1]?	p. 105
The Three Possible Alternate Hypotheses	p. 106
Test Concerning the Mean [mu] of a Normal Population When [sigma] Is Not Known	p. 107
Test for Difference of Two Means When [sigma]s Are Known	p. 107
Tests for Normality	p. 109
Use of the Normal Probability Plot	p. 110
Normal Probability Plot on the Computer	p. 112
A Goodness-of-Fit Test	p. 113
The P Value	p. 114
Exercises in Inference Methods	p. 115
Mini-Project 2.1	p. 117
Mini-Project 2.2	p. 118
References	p. 119
Quality in Design	p. 120
Planning for Quality	p. 120
The Product Creation Cycle	p. 120
Product Planning	p. 122
Finding Customer Needs	p. 122
Quality Function Deployment	p. 126
Reliability Fundamentals	p. 131
Product Design	p. 140
Parameter Design	p. 140
Design of Experiments	p. 141
Tolerance Design	p. 156
Failure Mode and Effect Analysis	p. 161
Concurrent Engineering	p. 164
Process Design	p. 166
The Process Flow Chart	p. 167
Process Parameter Selection: Experiments	p. 169
Floor Plan Layout	p. 173
Process FMEA	p. 173
Process Control Plan	p. 173
Other Process Plans	p. 175
Exercises	p. 178
Mini-Project 3.1	p. 181
Mini-Project 3.2	p. 181
Mini-Project 3.3	p. 181
References	p. 182
Quality in Production: Process Control-I	p. 184
Process Control	p. 184
The Control Charts	p. 185
A Typical Control Chart	p. 186
Measurement Control Charts	p. 188
X- and R-Charts	p. 189
A Few Notes About the X- and R-Charts	p. 194
X- and S-Charts	p. 205
Attribute Control Charts	p. 209
The P-Chart	p. 209
The C-Chart	p. 212
Some Special Attribute Control Charts	p. 214
The P-Chart with Varying Sample Size	p. 214
The nP-Chart	p. 217
The Percent Defectives Chart (100P-Chart)	p. 218
The U-Chart	p. 218
A Few Notes About the Attribute Control Charts	p. 221
Summary of Control Charts	p. 223
Implementing SPC on Processes	p. 224
Process Capability	p. 229
Capability of a Process with Measurable Output	p. 229
Capability Indices C[subscript p] and C[subscript pk]	p. 229
Capability of a Process with Attribute Output	p. 233
Measurement System Analysis	p. 234
Properties of Instruments	p. 234
Measurement Standards	p. 236
Evaluating an Instrument	p. 237
Exercises	p. 246
Mini-Project 4.1	p. 250
Mini-Project 4.2	p. 250
References	p. 251
Quality in Production: Process Control-II	p. 253
Derivation of Limits	p. 254
Limits for the X-Chart	p. 254
Limits for the R-Chart	p. 257
Limits for the P-Chart	p. 258
Limits for the C-Chart	p. 259
Operating Characteristics of Control Charts	p. 259
Operating Characteristics of an X-Chart	p. 259
OC Curve of an R-Chart	p. 262
Average Run Length	p. 263
OC Curve of a P-Chart	p. 266
OC Curve of a C-Chart	p. 268
Measurement Control Charts for Special Situations	p. 269
X- and R-Charts When Standards for [mu] and/or [sigma] Are Given	p. 269
Control Charts for Slow Processes	p. 274
Control Chart for Individuals (X-Chart)	p. 274
Moving Average and MR Charts	p. 276
The Exponentially Weighted Moving Average Chart	p. 279
Control Charts for Short Runs	p. 286
The DNOM Chart	p. 287
The Standardized DNOM Chart	p. 289
Topics in Process Capability	p. 291
The C[subscript pm] Index	p. 292
Confidence Interval for Capability Indices	p. 294
Motorola's 6[sigma] Capability	p. 296
Topics in Design of Experiments	p. 300
Analysis of Variance	p. 300
The General 2[subscript k] Design	p. 306
2[superscript 4] Design	p. 306
Fractional Factorials: One-Half Fractions	p. 308
Exercises	p. 318
Mini-Project 5.1	p. 321
Mini-Project 5.2	p. 321
References	p. 322
Managing for Quality	p. 323
Managing Human Resources	p. 323
Importance of Human Resources	p. 323
Organizations	p. 324
Quality Leadership	p. 327
Customer Focus	p. 329
Open Communications	p. 331
Empowerment	p. 332
Education and Training	p. 334
Teamwork	p. 339
Motivation Methods	p. 346
Principles of Management	p. 347
Strategic Planning for Quality	p. 347
History of Planning	p. 347
Making the Strategic Plan	p. 349
Strategic Plan Deployment	p. 351
Exercise	p. 351
Mini-Project 6.1	p. 351
References	p. 351
Quality in Procurement	p. 353
Importance of Quality in Supplies	p. 353
Establishing a Good Supplier Relationship	p. 354
Essentials of a Good Supplier Relationship	p. 354
Single vs. Multiple Suppliers	p. 354
Choosing a Supplier	p. 356
Certifying a Supplier	p. 357
Specifying the Supplies Completely	p. 357
Auditing the Supplier	p. 358
Supply Chain Optimization	p. 359
Using Statistical Sampling for Acceptance	p. 363
The Need for Sampling Inspection	p. 363
Single Sampling Plans for Attributes	p. 365
The Operating Characteristic Curve	p. 365
Designing an SSP	p. 368
Double Sampling Plans for Attributes	p. 371
MIL-STD-105E	p. 377
Average Outgoing Quality Limit	p. 380
Some Notes About Sampling Plans	p. 391
Exercises	p. 392
References	p. 393
Continuous Improvement of Quality	p. 395
The Need for Continuous Improvement	p. 395
The Problem-Solving Methodology	p. 396
Deming's PDCA Cycle	p. 396
Juran's Breakthrough Sequence	p. 398
The Generic Problem-Solving Methodology	p. 399
Quality Improvement Tools	p. 402
Cause-and-Effect Diagram	p. 402
Brainstorming	p. 403
Benchmarking	p. 404
Pareto Analysis	p. 408
Histogram	p. 410
Control Charts	p. 411
Scatter Plots	p. 412
Regression Analysis	p. 414
Correlation Analysis	p. 424
Exercises	p. 428
Term Project 8.1	p. 430
References	p. 430
A System for Quality	p. 431
The Systems Approach	p. 431
Dr. Deming's System	p. 432
Long-Term Planning	p. 433
Cultural Change	p. 434
Prevention Orientation	p. 434
Quality in Procurement	p. 434
Continuous Improvement	p. 435
Training, Education, Empowerment, and Teamwork	p. 436
Dr. Juran's System	p. 440
Quality Planning	p. 441
Quality Control	p. 443
Quality Improvement	p. 444
Dr. Feigenbaum's System	p. 447
Baldrige Award Criteria	p. 450
Leadership	p. 452
Strategic Planning	p. 453
Customer and Market Focus	p. 454
Measurement, Analysis, and Knowledge Management	p. 454
Human Resource Focus	p. 455
Process Management	p. 456
Business Results	p. 458
ISO 9000 Quality Management Systems	p. 459
The ISO 9000-2000 Family of Standards	p. 459
The Eight Quality Management Principles	p. 460
Documentation in ISO 9000	p. 462
ISO 9001-2000 Requirements	p. 462
Quality Management System	p. 463
Management Responsibility	p. 464
Resource Management	p. 466
Product Realization	p. 467
Measurement, Analysis, and Improvement	p. 471
The Six Sigma System	p. 474
Six Themes of Six Sigma	p. 474
The 6[sigma] Measure	p. 476
The Three Strategies	p. 477
The Two Improvement Processes	p. 478
The Five-Step Road Map	p. 478
The Organization for Six Sigma	p. 481
Summary of Quality Management Systems	p. 481
Exercises	p. 483
Mini-Project 9.1	p. 485
Mini-Project 9.2	p. 485
References	p. 485
Statistical Tables	p. 486
Answers to Selected Exercises	p. 496
Index	p. 505
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