The Quality Technician's Handbook

by Griffith, Gary K.

• ISBN13: 9780136742500
• ISBN10: 0136742505
• Edition: 4th
• Format: Hardcover
• Copyright: 2000-01-01
• Publisher: Prentice Hall

Summary

An ASQ best-seller, this text covers a variety of the basic skills that contribute to outgoing quality at the technician level. It is now one of the primary reference books used by people taking the ASQ Certification Exams.

Table of Contents

Introduction to Quality	1	(10)
The Quality Organization	2	(1)
Quality Systems	2	(3)
Quality and Communication	5	(1)
Motivation (Human Factors) and Quality	6	(2)
Review Questions	8	(2)
Total Quality Management	10	(29)
Quality Functions	11	(1)
Responsibility for Quality	12	(10)
TQM Tools	22	(8)
A Systematic Approach to TQM	30	(2)
Management Involvement and Commitment	32	(1)
Metrics	33	(1)
Problem Solving	34	(1)
Summary	34	(1)
Review Questions	35	(4)
Quality Costs	39	(12)
Categories of Quality Costs	39	(1)
Quality Cost Relationships	40	(1)
Pareto's Law and Quality Costs	41	(2)
Graphs, Charts, and Quality Costs	43	(1)
Prevention: The Return on Quality Investment (ROQI)	44	(2)
Quality Cost Reporting	46	(1)
Quality Cost System Results	47	(2)
Review Questions	49	(2)
Quality Audits	51	(12)
Why Audit?	51	(1)
Key Steps of the Auditing Process	52	(1)
Audit Findings and Observations	52	(1)
Types of Quality Audits	52	(1)
Audit Approaches and Purposes	53	(1)
Auditors and Audit Teams	54	(1)
Planning the Audit	55	(1)
Coducting the Audit	56	(2)
Audit Reporting	58	(1)
Corrective Action	59	(1)
Closing the Audit	60	(1)
Review Questions	60	(3)
Inspection Systems and Planning	63	(20)
Inspection Systems	63	(1)
Inspection Points	64	(2)
Inspection Personnel	66	(1)
Inspection Planning	66	(14)
Review Questions	80	(3)
Reading Engineering Drawings	83	(20)
Lines on an Engineering Drawing	83	(4)
Orthographic Projection Views	87	(2)
Change Block, Notes, and Tabular Dimensions	89	(2)
The Title Block	91	(1)
Rules to Follow When Using Engineering Drawings	92	(1)
Tolerances	93	(2)
Allowances and Fits	95	(1)
Threads (Nomenclature)	96	(2)
Chamfers	98	(1)
Review Questions	99	(4)
Geometric Dimensioning and Tolerancing	103	(56)
Comparison of ANSI Y14.5 Symbols	105	(1)
Other Drawing Symbols	105	(1)
The Dimension Origin Symbol	105	(5)
Maximum Material Condition---Least Material Condition	110	(2)
The Virtual Condition	112	(2)
General Rules for ASME Y14.5M---1994 Tolerancing	114	(1)
Inspecting Size Tolerances per ASME Y14.5 Rule 1	115	(1)
Datums	116	(2)
Datum Targets	118	(4)
How to Contact Feature Datums	122	(1)
Coordinate Method of Positioning Features	123	(2)
Position Tolerancing	125	(3)
When Features Are Out of Position Tolerance	128	(3)
Converting Position Tolerances to Coordinate Tolerances	131	(2)
Understanding Bonus Tolerancing	133	(2)
Additional Tolerance from Size Datums	135	(1)
Chain, Baseline, and Direct Dimensioning	135	(1)
Composite Position Tolerances	136	(1)
Position Tolerance Stated at LMC	137	(2)
Zero Position Tolerances at MMC	139	(1)
Bidirectional Position Tolerances	140	(2)
Position: Fixed and Floating Fastener Cases	142	(2)
Projected Tolerance Zones	144	(2)
Functional Gages	146	(4)
The Chain Line	150	(2)
Changes in the Geometric Tolerancing Standard	152	(1)
Review Questions	152	(7)
Graphical Inspection Analysis	159	(30)
Geometric Tolerancing Principles	159	(9)
Graphical Inspection Analysis Procedure	168	(10)
Work Problems	178	(4)
Graphical Inspection Analysis Advantages	182	(4)
Computer Inspection Analysis	186	(1)
Review Questions	187	(2)
Common Measuring Tools and Measurements	189	(78)
Dimensional Measurement	189	(1)
Measuring Tools	189	(2)
Measurements and Accuracy	191	(2)
Types of Measurement Errors	193	(1)
The Steel Rule	193	(2)
Spring Calipers	195	(1)
Gage Blocks	196	(3)
Mechanical Indicators	199	(5)
Cosine Error in Indicators	204	(2)
TIR, FIR, and FIM	206	(1)
Dial Indicating Gages	207	(11)
Micrometers	218	(12)
Vernier Instruments	230	(3)
Telescoping Gages	233	(4)
Small Hole Gages	237	(1)
Attribute Gages	237	(7)
Radius Gages	244	(1)
Tapered (Adjustable) Parallels	245	(3)
Centerline Attachments	248	(3)
Mechanical Comparators	251	(4)
Measuring and Gaging Internal Threads	255	(1)
Measuring and Gaging External Threads	256	(2)
Measuring Threads: The Three-Wire Method	258	(3)
Basic Calibration Techniques	261	(1)
Review Questions	262	(5)
Surface Plate Inspection Methods	267	(37)
Surface Plates	267	(3)
Fixed Parallels	270	(2)
Care of Surface Plates	272	(1)
Surface Gages	272	(3)
Possible Sources of Errors in Measurement	275	(1)
Making Linear Measurements Using the Transfer Method or the Direct Reading Method	275	(3)
Centerline Measurement of Features	278	(1)
Parallelism Measurement	279	(2)
Flatness Measurement	281	(2)
Concentricity Measurement	283	(1)
Runout Tolerances	284	(3)
Perpendicularity (Squareness) Measurement	287	(2)
Coaxiality Measurement (Using Position Tolerance)	289	(1)
Angularity Measurement: Angularity versus Simple Angles	290	(4)
Symmetry	294	(2)
Straightness (of an Axis)	296	(2)
Straightness Measurement: Straightness of Surface Elements	298	(1)
Using Profile Tolerances for Coplanarity	299	(1)
Review Questions	300	(4)
Special Measuring Equipment and Techniques	304	(48)
Digital Measuring Equipment	304	(1)
Flatness Measurement (Using Optical Flats)	305	(5)
Mesuring Surface Finish	310	(8)
Pneumatic Comparators (Air Gages)	318	(3)
Circularity (Roundness) Measurement	321	(3)
Cylindricity	324	(2)
Free State Variation	326	(2)
Optical Comparators (Profile Tolerances)	328	(4)
Profile Tolerances per ANSI Y14.5M---1982	332	(3)
Coordinate Measuring Machines	335	(5)
Torque Measurement	340	(2)
Hardness Testing	342	(6)
Review Questions	348	(4)
Lot-by-Lot Acceptance Sampling Plans	352	(47)
Basic Probability	352	(4)
Sample Statistics versus Population Parameters	356	(1)
Probability Distributions for Attributes	357	(4)
Relationships Between Sampling and 100% Inspection	361	(2)
Lot-by-Lot Acceptance Sampling versus Process Control Sampling	363	(1)
Random Sampling	364	(3)
Using ANSI/ASQC Z1.4 for Sampling Inspection	367	(6)
Introduction to Dodge-Romig Sampling Tables	373	(1)
ANSI/ASQC Z1.9 Variables Sampling Tables	374	(15)
Operating Characteristic (OC) Curves	389	(5)
Review Questions	394	(5)
Statistical Process Control	399	(84)
Objectives of SPC	399	(1)
Tools for Process Control	400	(1)
The Importance of Distribution	401	(5)
Measures of Central Tendency	406	(3)
Measures of Dispersion (Variation)	409	(4)
Computing the Average, Range, and Standard Deviation with Negative Numbers in the Data	413	(2)
Definition of a Process in Control	415	(1)
Control Limits versus Specification Limits	416	(2)
Table for the Initial Selection of Subgroup Sizes and Intervals	418	(1)
Various Plotting Errors to Avoid	418	(1)
How Measurement Errors Affect Charts	419	(1)
Importance of Rational Subgroups	419	(1)
How Calculation Errors Affect Charts	420	(1)
Guidelines for Starting an Average and Range Control Chart	421	(4)
Average and Sigma Charts	425	(3)
Median Control Charts	428	(2)
Control Charts for Individuals and Moving Ranges	430	(4)
Attribute Control Charts	434	(16)
Interpreting Control Charts: Pattern Analysis	450	(5)
Process Capability	455	(15)
Gage Repeatability and Reproducibility Studies	470	(7)
Miscellaneous Topics	477	(2)
Review Questions	479	(4)
Shop Mathematics	483	(58)
Adding and Subtracting Fractions	483	(5)
Multiplying and Dividing Fractions	488	(1)
Working with Decimals	489	(3)
Adding and Subtracting Angles	492	(2)
Working with Equations	494	(2)
The Circle	496	(6)
Perimeters	502	(2)
Areas	504	(3)
Volumes	507	(3)
Solving the Right Triangles for Sides Only: The Pythagorean Theorem	510	(3)
Solving the Right Triangle	513	(8)
Memorizing the Trigonometry Formulas for the Right Triangle	521	(1)
Solving Oblique Triangles	522	(4)
Tapers	526	(5)
Units of Measurement	531	(1)
Metric of English: A Comparison	532	(2)
Ratios	534	(1)
Temperature Conversion	534	(2)
The Real Number Line	536	(1)
The Cartesian Coordinate System	536	(2)
Scientific Notation	538	(1)
Review Questions	539	(2)
Glossary A Quality Terms and Definitions	541	(8)
Glossary B Various Manufacturing Processes	549	(4)
Glossary C Terms Used in Reliability	553	(4)
Glossary D Overview of Nondestructive Evaluation (NDE) Methods	557	(2)
Bibliography	559	(2)
Appendix Tables	561	(6)
Subject Index	567	(10)
Formulas Index	577