Table of Contents

Course Guide ix xiii

Topic 1 Introduction to Quality 1

1.1 History of Quality 2
1.2 Definitions 7
1.3 Quality Gurus 11
1.3.1 Dr Walter A. Shewhart 12
1.3.2 Dr W. Edwards Deming 14
1.3.3 Dr Joseph M. Juran 20
1.3.4 Dr Armand V. Feigenbaum 22
1.3.5 Philip Crosby 23
1.3.6 Dr Kaoru Ishikawa 24
1.3.7 Dr Genichi Taguchi 26
Summary 27
Key terms 28
References 28

Topic 2 Basic Statistics 29
2.1 Statistics and Quality 29
2.2 Frequency Distribution 30
2.2.1 Characteristics of Frequency Distribution Graphs 32
2.3 Measures of Central Tendency 33
2.4 Measures of Dispersion 35
2.4.1 Relationship Between the Measures of Dispersion 37
2.5 Population and Sample 38
2.6 Normal Curve 42
Summary 50
Key Terms 50
References 50

Topic 3 Basic Probability 51

3.1 Definition of Probability 51
3.2 Probability Theorems 53
3.3 Permutations and Combinations 60
3.4 Discrete Probabilistic Distributions 62
3.4.1 Hyper-Geometric Probability Distribution 63
3.4.2 Binomial Probability Distribution 64
3.4.3 Poisson Probability Distribution 66
3.5 Continuous Probabilistic Distributions 67
3.5.1 Normal Probability Distribution 68
3.6 Distribution Interrelationships 68

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Summary 71
Key Terms 71
References 71

Topic 4 Statiscal Process Control (SPC) Tools 72

4.1 The Magnificent Seven 73
4.2 Check Sheet 74
4.3 Pareto Diagram 75
4.4 Cause and Effect Diagram 78
4.5 Process Flow Diagram 79
4.6 Scatter Diagram 82
4.7 Histogram 85
4.8 Control Charts 86
Summary 88
Key Terms 88
References 89

Topic 5 SPC Tools Control Charts 90

5.1 What is a Control Chart? 91
5.2 Variation 94
5.2.1 Common Cause Variation 94
5.2.2 Special Cause Variation 95
5.3 Run Charts 97
5.4 Control Charts for Variables 99
5.4.1 Subgroup Concept 99
5.4.2 Steps in Constructing Variable Control Charts 100
5.4.3 Average and Range Charts ( X and R Charts) 101
5.4.4 X-Bar and Standard Deviation Charts
( X and s Charts) 105
5.5 Control Charts for Attributes 108
5.5.1 Steps in Constructing an Attributes Control Chart 108
5.5.2 Fraction Non-Conforming Charts (p Charts) 109
5.5.3 Number of Non-Conforming Charts (np Charts) 112
5.5.4 Number of Non-Conformities Charts (c Charts) 114
5.5.5 Number of Non-Conforming Per Unit Charts
(u Charts) 116
5.6 Control Chart Interpretations 119
5.7 Re-Baseline the Process 122
Summary 123
Key Terms 123
References 123

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Topic 6 Process Capability 124

6.1 Process Capability 124
6.2 Steps in Process Capability Study 126
6.2.1 Inherent Capability 126
6.2.2 Cp Index 128
6.2.3 Cpk Index 131
Summary 136
Key Terms 137
References 137

Topic 7 Failure Mode and Effect Analysis (FMEA) 138

7.1 Failure Mode and Effect Analysis (FMEA) 139
7.2 Historical Review 140
7.3 Application of FMEA 140
7.4 Benefits of FMEA 141
7.5 FMEA and Quality Management Systems (QMS) 142
7.6 FMEA Timing 143
7.7 FMEA Methodology 143
7.7.1 Risk Priority Numbers (RPN) 144
7.8 FMEA Success and Failure 149
Summary 151
Key Terms 152
References 152

Topic 8 Advanced Subjects in Quality Control 153

8.1 Design of Experiments (DOE) 153
8.1.1 What is DOE? 154
8.1.2 Benefits and Applications of DOE 156
8.1.3 Definitions 157
8.1.4 Basic Steps in DOE 158
8.1.5 Types of Experiments 158
8.1.6 Factorial Experiments 164
8.2 Acceptance Sampling 165
8.2.1 Advantages and Disadvantages of Sampling 166
8.2.2 Types of Acceptance Sampling Plans 167
8.3 Reliability 169
8.3.1 Systems Reliability (Rs) 170
Summary 172
Key Terms 172
References 172

Appendices 175

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