MENG 3402-02

Quality & Process Control

Lecture #1
Syllabus and Introduction to Quality Control
Todays lecture
About this course
Textbook
Topics covered and tentative schedule
Grading
What is quality?
Eight dimensions of quality
Critical-to-Quality Characteristics
Statistical Methods for Quality improvement
Quality Management Systems
About the Instructor
Dr. Tamer Farouk Abdelmaguid
Visiting Associate Professor, Mechanical Engineering
Department, AUC.
Prior position: Associate Professor, Department of Mechanical
Design and Production, Faculty of Engineering, Cairo
University.
PhD, University of Southern California 2004
E-mail address: tabdelmaguid@aucegypt.edu
Office Hours: MR 8:30-9:30 AM
& R 3:30-4:30 PM
or by appointment
Office: SSE 2029
About this course
Quality & Process Control

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.

Prerequisite: MACT 317 - Probability and Statistics (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
Course outcomes
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 experiments for process design.
Textbook

Montgomery, Douglas C., Statistical Quality Control A Modern

Introduction, Seventh Edition, 2013, John Wiley & sons, ISBN:
978-0470-23397-9.
Software
Minitab is a leading statistical package developed at the
Pennsylvania State University. It is easy to use and is
equipped with all the tools required to conduct all
calculations and analysis required for this course.
Students are required to use Minitab in all Lab experiments.
The use of a computer and/or iPad/Tablet is encouraged,
where you can download lectures, assignments, and
solved problems from blackboard and bring to class for
discussion.
References
Power Point presentation posted on blackboard
Quality and Process Control Lab Manual
Minitab Tutorial
Email policy
Please include in the Subject line the course code
MENG 3402 and a concise and clear statement of
purpose; otherwise it may be deleted, along with spam
messages and messages potentially containing viruses.
Course Calendar
Week Date Topic Reference in Textbook
Course Outline & Introduction to QC
- History and evolution of QC
Chapters 1 & 2
1-2 Sep 7 14
- Statistical Methods for QC
- TQM & Six Sigma
Review of Statistics
- Descriptive statistics
- Describing variation
- Important discrete distributions
3 -5 Sep 18 Oct 5 - Important continuous distributions Chapters 3 & 4
- Sampling distributions
- Estimation of process parameters
- Goodness of fit
- Hypothesis testing on process parameters
Methods and Philosophy of Statistical Process Control SPC
- Statistical basis of the control chart
6 Oct 9 12 Chapter 5
- The Magnificent Seven
MIDTERM EXAMINATION I
Control Charts for Variables:
- X and R control chart
7- 8 Oct 16 26 - X and S control chart Chapter 6
- S2 control chart
- Control charts for individual measurements

Control chart for Attributes

9 - 10 Oct 30 Nov 9 - Control Chart for Fraction Non-Conforming Chapter 7
- Control Chart for Non-conformities

11 Nov 13 - 16 MIDTERM EXAMINATION II

12 Nov 20 - 23 Process Capability Analysis Chapter 8
13 -14 Nov 27 - Dec 7 Design of Experiments Chapter 13
15 Dec 11 - 14 Cumulative Sum and Exponentially Weighted Moving Average Control Charts Chapter 9
Lab Calendar
Week Dates Topic

2-3 Sep. 10 21 (2 weeks) Introduction to Minitab

4 Sep 24 - 28 1. Descriptive statistics

5 Oct 1 5 2. Normal Probability Plots & goodness of fit test

6 3. Calibration of measuring instruments using Inverse

Oct 8 12
Regression Analysis
7-8 Oct 15 - 26 (2 weeks) 4. Confidence interval & testing of hypothesis

9 - 10 Oct 29 Nov 9 (2 weeks) 5. Control chart for variables

11 -12 Nov 12 23 (2 weeks) 6. Control chart for attributes

13 Nov 26 - 30 7. Process Capability Analysis, R&R Experiment

14 Dec 3 - 7 8. Design of Experiments

 Important dates

September:
- This class begins, Thursday, September 7th, 2017.
- Islamic New Year (H), Thursday, September 21st, 2017 (to be confirmed).
October:
- Deadline to drop courses, Thursday, October 26th, 2017.
November:
- Deadline for Withdrawal, Wednesday, November 22nd, 2017.
- Thanksgiving (H), Tursday, November 23rd, 2017
- ElMawled ElNabawy (H), Thursday, November 30th, 2017 (to be confirmed).
December:
- Last day for this class, Thursday, December 14th, 2017.
- Dec 16 21 Semester Final Examination.
Grading

Assignments 12 %
Quizzes 12 %
Lab Experiments 16 %
Midterm 1 15 %
Midterm 2 15 %
Final Exam 30 %

The grades in MENG 3402 will be awarded as follows:

90% - 92.99% = A- 93% or better = A

80% 82.99% = B- 83% - 86.99% = B 87% - 89.99% = B+
70% 72.99% = C- 73% - 76.99% = C 77% - 79.99% = C+
60% 64.99% = D 65% - 69.99% = D+
below 60% = F
Assignments
Assignments are where course material is understood
and mastered.
You can expect to gain most of your in-depth
understanding and ability to solve problems quickly by
studying your class notes, reviewing sample problems and
working assignment problems.
Assignments prepare you for quizzes and exams and
prepare you for future lectures.
Failure to work on assigned problems will result in
needless errors on quizzes, exams, and future
assignments.
Assignments tentative schedule

Assignment Chapter Problems Tentative Due Date

1 3 Handout Sep 27, 2017
2 4 Handout Oct 4, 2017
3 6 Handout Oct 25, 2017
4 7 Handout Nov 9, 2017
5 8 Handout Nov 29, 2017
6 13 Handout Dec 6, 2017
Quizzes
Quizzes will be given at selected dates covering recent
material discussed in class.
An announcement will be made one week prior to each
quiz. No make-up allowed if you miss a quiz.
Two midterms
Midterm Exam I will be given on Thursday, October 12th,
2017.
Midterm Exam II will be given on Thursday, November
16th, 2017.
Final
The final exam will be comprehensive
Ethics
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.
Students are expected to do their own work on
assignments quizzes and exams. Although studying in
groups is encouraged, outright copying of another
persons work is unethical, unprofessional AND
VIOLATES UNIVERSITY POLICY REGARDING
ACADEMIC INTEGRITY.
What is Quality?
Definitions of quality that represent different points of view
are:
User-based definition: quality is determined by what a customer wants and
what he/she is willing to pay for (namely, customer satisfaction). Here,
quality is defined as Fitness for intended use. To determine fitness for
intended use, one must consider issues such as the products intended
use, frequency of use, cost, performance, reliability, and serviceability
requirements.
Manufacturing-based definition: Quality is conformance to specifications.
Specifications are targets (ideal values) and tolerances determined by
designers of products and services. For example, a shaft diameter is
specified as 500.01 mm. The target is 50mm and the allowable variation
is 0.01 below and above.
What is Quality?
Definitions of quality that represent different points of view
(continued):
relative quality: Quality = Superiority or innate excellence. It is often
loosely related to a comparison of features and characteristics of
products of the same category. This definition, however, can not be used
at the operational level since quality can not be measured, compared or
controlled.
Product-based definition: quality is a precise and measurable variable and
that differences in quality reflect differences in quantity of some product
attribute. Ex: the number of cylinders in an engine, the speed of the
processor, the resolution of the screen, a three-star versus five-star
hoteletc. Here, quality is directly proportional to the cost of a product,
which may not always be true.
What is Quality?
Definitions of quality that represent different points of view
(continued):
Value-based definition: a quality of product is one that provides
performance at an acceptable price or conformance at an acceptable
cost. For example we can tighten the specification limits to 0.0001 mm
in the previous example by using very advanced and expensive
manufacturing machine. This may not be considered quality in
manufacturing if this tolerance is really not required. This definition is
difficult to apply in practice, however, since it incorporates two distinct
concepts quality and value.
Eight Dimensions of Quality
The various definitions of quality can be explained by
examining eight principal quality dimensions which are:
1. Performance: Will the product do the intended job
with advantages in performance?
2. Reliability: How often does the product fail?
3. Durability: How long does the product last?
4. Serviceability: How easy is it to repair a product?
5. Aesthetics: What does the product look like?
6. Features: What does the product do?
7. Perceived Quality: What is the reputation of the
company or its product?
8. Conformance to Standards: Is the product made
exactly as the designer intended?
 Quality traditionally means fitness for use, which has two
general aspects
- Quality of design
- Quality of conformance
The modern concept of quality is quality is inversely
proportional to variability

Quality Improvement: Reduction of variability in processes

and products (elimination of waste)
Critical-to-Quality Characteristics
Elements that jointly describe what the consumer thinks
of as quality:

Physical: length, weight, voltage, viscosity

Sensory: taste, appearance, color
Time Orientation: reliability, durability, serviceability

These can be directly or indirectly related to the dimensions of quality.

Variability in Quality Characteristics
Most manufacturers find it difficult (and expensive) to
provide the customer with products that have always
identical quality characteristics from unit to unit.
Variability is unavoidable, but can be measured and
controlled with the help of statistical methods.
Specifications
Target or nominal values
Lower specification limit
Upper specification limit
Defect versus nonconformity: Products not meeting the
specification limits are not necessarily defective
History of Quality Improvement
Statistical Methods for Quality Improvement
Statistical Methods
Statistical process control (SPC)
Control charts, plus other problem-solving tools
Useful in monitoring processes, reducing variability through
elimination of assignable causes
On-line technique
Designed experiments (DOX)
Discovering the key factors that influence process
performance
Process optimization
Off-line technique
Acceptance Sampling
Walter A. Shewart (1891-1967)
Trained in engineering and physics
Long career at Bell Labs
Developed the first control chart
about 1924
A factorial experiment with three factors
Quality Management Systems
Effective management of quality requires the execution of
three activities:
1. Quality Planning
2. Quality Assurance
3. Quality Control and Improvement
Quality Philosophies and
Management Strategies
W. Edwards Deming

Taught engineering, physics in the

1920s, finished PhD in 1928
Met Walter Shewhart at Western
Electric
During WWII, he worked with US
defense contractors, deploying
statistical methods
Sent to Japan after WWII to work
on the census
Deming
Deming was asked by the Japanese Union of Scientists
and Engineers (JUSE) to lecture on statistical quality
control to management
Japanese adopted many aspects of Demings management
philosophy
Deming stressed continual never-ending improvement
Deming lectured widely in North America during the
1980s; he died 24 December 1993
Demings 14 Points
1. Create constancy of purpose toward improvement
2. Adopt a new philosophy, recognize that we are in a time of
change, a new economic age
3. Cease reliance on mass inspection to improve quality
4. End the practice of awarding business on the basis of price
alone
5. Improve constantly and forever the system of production and
service
6. Institute training
7. Improve leadership, recognize that the aim of supervision is
help people and equipment to do a better job
8. Drive out fear
9. Break down barriers between departments
14 Points continued

10. Eliminate slogans and targets for the workforce such as zero
defects
11. Eliminate work standards
12. Remove barriers that rob workers of the right to pride in the
quality of their work
13. Institute a vigorous program of education and self-
improvement
14. Put everyone to work to accomplish the transformation

Note that the 14 points are about change

Demings Deadly Diseases
1. Lack of constancy of purpose
2. Emphasis on short-term profits
3. Performance evaluation, merit rating, annual
reviews
4. Mobility of management
5. Running a company on visible figures alone
6. Excessive medical costs for employee health care
7. Excessive costs of warrantees
Joseph M. Juran
Born in Romania (1904),
immigrated to the US
Worked at Western Electric,
influenced by Walter
Shewhart
Emphasizes a more strategic
and planning oriented
approach to quality than
does Deming
Juran Institute is still an
active organization
promoting the Juran
philosophy and quality
improvement practices
The Juran Trilogy
1. Planning
2. Control
3. Improvement

These three processes are interrelated

Control versus breakthrough
Project-by-project improvement
Some of the Other Gurus
Kaoru Ishikawa
Son of the founder of JUSE, promoted widespread use of
basic tools
Armand Feigenbaum
Author of Total Quality Control, promoted overall
organizational involvement in quality
Three-step approach emphasized quality leadership, quality
technology, and organizational commitment
Total Quality Management (TQM)
Started in the early 1980s, Deming/Juran philosophy as
the focal point
Emphasis on widespread training, quality awareness
Training often turned over to HR function
Not enough emphasis on quality control and
improvement tools, poor follow-through, no project-by-
project implementation strategy
TQM was largely unsuccessful
Quality Standards
International Standard Organization (ISO) in 1987

ISO 9000:2000 Quality Management System Fundamentals and Vocabulary

ISO 9001:2000 Quality Management System Requirements
ISO 9004:2000 Quality Management System Guidelines for Performance
Improvement

A company can be certified by selecting a registrar and receiving a certification

audit. Once certified, the company also receives periodic surveillance audits.
 The ISO certification process focuses heavily on quality
assurance, without sufficient weight given to quality planning and
quality control and improvement
The Malcolm Baldrige National Quality Award

The MBNQA process is a valuable assessment tool

See Table 1-4 for Performance Excellence Criteria and point values
Quality Improvement Role in All Elements of
Production Systems