BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

COURSE HANDOUT

Academic Term
Course Title
Course ID No.
Instructor(s)

SECOND SEMESTER 2014-2015

Quality Control Assurance & Reliability
ET ZC432
C Phaneendra Kiran

Course Modules (add more rows as per needs)

Module
No

Module Title

Objectives

Introduction to Quality Control and

Total Quality System

To define quality, introduce terminology,

framework for design and implementation
of quality,

2,3

Quality costs and Introduction to

quality philosophy, Some philosophies
and their impact on quality

activity based product costing, unique

quality characteristics for service sector,
study various philosophies on quality

Quality Management : Practices, Tools

and standards

Framework for management to assure

quality, principle of TQM, quality function
deployment, benchmarking, quality tools,
quality standards

5,6

Fundamental of Statistical concepts and Statistical concepts: descriptive, inferential

statistics
techniques in quality control and
improvement
Graphical methods of Data presentation Variable tools for analysing product and
process data, test for distributional
and quality improvement
assumptions, analyse quality data

10&11

Statistical process control using control

charts

Principles of control charts, basic features

of control charts, inferential errors, and
how they can be reduced

Control chart for variables

To study control charts for the quality

characteristics which are measurable on a
numerical scale eg: diameter

12

Control chart for attributes

To study control charts for the quality

characteristics which are not measurable
on a numerical scale eg: aroma of coffee

13

Process capability analysis

To study some commonly used process

capability measures, procedure for
computation, interpret them

Acceptance sampling plans for

attributes and variables

Examining acceptance sampling and

procedures for product acceptance or
rejection

16

Reliability

Study reliability calculation of system with

different types of components: series,
parallel, standby

17

Experimental design and Taguchi

method

Procedures used to control the offline

quality at the design stage are discussed

14&15

Text Book(s)
T1

T1

Mitra Amitava, Fundamentals of Quality Control and Improvement,

Prentice Hall of India, 3rd Ed., 2008.

T2

Reference Book(s) & other resources

R1

D.H. Besterfield et al., Quality Control, Pearson Education, 7 th Ed., 2004

R2

D.H. Besterfield et. al, Total Quality Management, Pearson Education, 2nd Edition,
2001

R3

Douglas C. Montgomery, Introduction to Statistical Quality Control, John Wiley &

Sons, 3rd Ed., 2001.

R4

James R. Evans, Total Quality Management, Organization, and Strategy, Thomson, 4th
Ed., 2007.

R5

James R. Evans, William M. Lindsay, The Management and Control of Quality,

Thomson, 6th Ed., 2006.

Self-Study & Contact Session Plan

Module Title: Introduction to Quality Control and Total Quality System

Session 1

Topic
No.

Topic Title

Reference

1.1

Introduction, Evolution of quality control, Quality,

Quality control, Quality assurance, Quality circle
and quality improvement teams

T1- Chapter 11.1,1.2,1.3,1.4,1.5,1.6,1.7

1.2

Benefits of quality control, responsibility for quality,

Reliability, Total quality system,

T1- Chapter 1-1.8,1.9,1.10

Module Title: Quality costs and Introduction to quality philosophy

Session 2
Topic
No.

Topic Title

Reference

2.1

Quality improvement, Quality costs Measuring

quality cost, Management of quality, Quality and
Productivity, Total quality environmental
management

T1- Chapter 1-1.10,1.11,1.12,1.13,

1.14,1.15,1.16

2.2

Introduction, W. Edwards Deming and his

contribution, Extended process

T1- Chapter 2-2.1,2.2

Module Title: Some philosophies and their impact on quality

Session 3
Topic
No.

Topic Title

Reference

3.1

Demings 14 points for management

T1- Chapter 2-2.4,

3.2

P. Crosbys philosophy, Joseph M.Juran Philosophy,

The three philosophies compared

T1- Chapter 2-2.5, 2.6, 2.7

Module Title: Quality Management : Practices, Tools and standards

Session 4
Topic
No.

Topic Title

Reference

4.1

Introduction, Management Commitment, QFD,

Innovative adaptation and performance evaluation:
benchmarking, quality auditing, vendor selection
process

T1- Chapter 3-3.1, 3.2, 3.3, 3.4

4.2

Tools for continuous quality improvement,

International standards ISO 9000:9004,TS16949,
Malcolm Baldrige National Quality Awards,

T1- Chapter 3-3.5, 3.6, 3.7

Module Title: Fundamental of Statistical concepts and techniques in quality control and improvement
Session 5
Topic
No.

Topic Title

Reference

5.1

Introduction, Population and sample, Parameter and

Statistics, Probability, Descriptive Statistics, Probability
Distribution,

T1- Chapter 4-4.1,4.2, 4.3 4.4, 4.5,

4.6

5.2

Problems solving

Module Title: Fundamental of Statistical concepts and techniques in quality control and improvement
(Contd..)
Session 6
Topic
No.

Topic Title

Reference

6.1

Inferential Statistics,

T1- Chapter 4-4.7

6.2

Problems solving

Module Title: Graphical methods of Data presentation and quality improvement

Session 7
Topic
No.
7.1

Topic Title

Reference

Introduction, Frequency distribution and Histograms, T1- Chapter 5-5.1,5.2, 5.3,

Run Charts, Stem and Leaf plots, Pareto Diagrams,
Cause and Effect Diagrams, Box plots,

7.2

Normal Probability plots, Empirical QuantileQuantile plots, Scatter Diagrams, Multivariable

charts, Matrix plots and Three dimensional Scatter
Plots

T1- Chapter 5-5.4

7.3

Concepts in Sampling

T1- Chapter 5-5.7

Module Title: Statistical process control using control charts

Session 8
Topic
No.

Topic Title

Reference

8.1

Introduction, Causes of variations, Statistical basis

for control charts, Selection of Rational Samples,

T1- Chapter 6-6.1,6.2, 6.3,6.4

8.2

Analysis of Patterns in Control Charts, Maintenance

of Control Charts

T1- Chapter 6-6.5, 6.6

Session 9: Review Session

Mid-Semester Test (Closed Book) : Topics in Session 1 to 8
Module Title: Control chart for variables:
Session 10
Topic
No.
10.1

Topic Title

Reference

T1- Chapter 7-7.1, 7.2, 7.3, 7.4

Introduction, Selection of Characteristics for
Investigation, Preliminary Decisions, Control Charts
for the Mean and Range

Module Title: Control chart for variables

Session 11
Topic
No.
11.1

Topic Title

Reference

Control Charts for Mean and Standard Deviation,

Control Charts for Individual Units, Other Control
Charts, Multivariate Control Charts

T1- Chapter 7-7.5, 7.6, 7.7, 7.8, 7.9

Module Title: Control chart for attributes

Session 12

Topic
No.

Topic Title

Reference

12.1

Introduction, Advantages and Disadvantages of

Attribute charts, Preliminary Decisions, Charts for
Proportion Nonconforming(p-Chart) ,np-charts,

T1- Chapter 8-8.1, 8.2, 8.3, 8.4,

8.5,

12.2

c-chart, u-chart, U-chart, Operating characteristics

curves for Attribute Control Charts

T1- Chapter 8-8.6, 8.7, 8.8, 8.10

Module Title: Process capability analysis

Session 13
Topic
No.

Topic Title

Reference

13.1

Introduction, Specification limits and Control Limits, T1- Chapter 9-9.1,9.2, 9.3,9.4
9.5,9.6 ,
Process Capability Analysis, Natural Tolerance
Limits, Specifications and Process Capability,
Process Capability Indices,

13.2

Process Capability Analysis Procedures, Setting

Tolerances on Assemblies and components,
Estimating Natural Tolerance Limits of a process.

T1- Chapter 9-9.7, 9.9,9.10

Module Title: Acceptance sampling plans for attributes and variables

Session 14
Topic
No.
14.1

Topic Title

Reference

Introduction, Advantages and Disadvantages of

Sampling, Producers Risk and Consumers Risk,
Operating Characteristics Curve, Types of Sampling
Plans, Evaluating Sampling Plans,

T1- Chapter 10-10.1, 10.210.3,

10.4,10.5, 10.6

Module Title: Acceptance sampling plans for attributes and variables

Session 15
Topic
No.

Topic Title

Reference

15.1

Lot-by-Lot Attribute Sampling Plans, Other Attribute T1- Chapter 10-10.8,10.9, 10.10,
10.11,10.12,10.13
Sampling Plans, Sampling Plans for Continuous
Production, Demings kpRule, Sampling plans for
Variables, Advantages and Disadvantages of Variable
Plans, Variable Sampling Plans for Process
Parameters, Variable Sampling Plans for for
estimating the Lot Proportion Nonconforming,
Standardized Plans

Module Title: Reliability

Session 16
Topic
No.
16.1

Topic Title

Reference

T1- Chapter 11
Introduction, Reliability, Life cycle curve and
probability distributions in Modeling Reliability,
System Reliability, Operating Characteristics Curves,
Reliability and Life Testing Plans

Module Title: Experimental design and Taguchi method

Session 17
Topic
No.
17.1

Topic Title

Reference

Introduction, Experimental design fundamentals,

T1-Chapter 12-12.1, 12.2 ,
Some experimental designs, factorial experiments, 12.3, 12.4, 12.5, 12.6, 12.7,
Taguchi method, Taguchi philosophy, Loss function, 12.8, 12.10
signal to noise ratio, experimental design in
Taguchi method

Session 18: Review Session

Details of Lab (Online) If any:
Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session
No

Name

Type

Durati
on

Weigh Day, Date, Session, Time

t

EC-1

Quiz-I

Online

15%

Quiz-II

February 1-10, 2015

March 1-10, 2015

Quiz-III

April 1-10, 2015

EC-2

Mid-Semester Test

Closed
Book

EC-3

Comprehensive Exam Open

Book

2
hours

35%

21/02/2015 (FN) 10 AM 12 NOON

3
hours

50%

18/04/2015 (FN) 9 AM 12 NOON

Syllabus for Mid-Semester Test (Closed Book): Topics in Session Nos. 1 to 8

Syllabus for Comprehensive Exam (Open Book): All topics (Session Nos. 1 to 18)
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the
latest announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on
the Elearn portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them
through the course pages on the Elearn portal. Announcements will be made on the
portal, in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed
or bound) is permitted. However, loose sheets of paper will not be allowed. Use of
calculators is permitted in all exams. Laptops/Mobiles of any kind are not allowed.
Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies,
the student should follow the procedure to apply for the Make-Up Test/Exam which will
be made available on the Elearn portal. The Make-Up Test/Exam will be conducted only
at selected exam centres on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study
schedule as given in the course handout, attend the online lectures, and take all the prescribed
evaluation components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam
according to the evaluation scheme provided in the handout.