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
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
Dates
Week Topic
Section 81 Other Sections
(Thursday) (S, M, T, W)

2-3 Sep. 14 Sep. 17 20 Introduction to Minitab

4 Sep 24 - 28 1. Descriptive statistics

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

3. Calibration of measuring instruments using
6 Oct 8 12
Inverse Regression Analysis
7 Oct 15 - 19 4. Confidence interval & testing of hypothesis

8 Oct 22 - 26 5. Control chart for variables

9 Oct 29 Nov 2 6. Control chart for attributes

10 Nov 9 7. Process Capability Analysis, R&R Experiment

11 Nov 16 8. Design of Experiments

12 Nov 19 - 22 7. Process Capability Analysis, R&R Experiment

13 Nov 26 - 29 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