Capability

1.33, 1.67, 2.00

Even numbers of sigma
Parts per million: Area under curve outside spec limits times 1 million
Never report decimals, round proper
Single Sided Tolerances
Flatness
Max/Min dimensions
Only one spec limit (either LSL or USL,) can only calculate Ppk
Cp/Cpk
Equations
Pp and Ppk equations, except Sigma has a little hat
Sigma hat estimates sigma based off of R-bar
Depends on chart used
Sigma Hat= R-bar/d2
Sigma Hat = MR-bar/d2
Ps come from 30 consecutive parts
Cs come from properly constructed control chart data
Failure Mode and Effect Analysis (FMEA)
-Predictive tool
-What could go wrong with that?
a. whats so bad about that? (Severity)
b. whats the chance that it could really happen? (Occurrence)
c. whats the chance wed catch that? (Detection)
-Steps
1. Form team
2. Timing: before work has begun
3. Focus
-System FMEA
1. Auto only of entire system
-Design FMEA
-Process FMEA
4. Document results.
Example - Flat blade screwdriver
1. System
a. Intended/Expected Uses
i. Turn screws
ii. Not strip screw
iii. Handle stays on
iv. Survive torsional load
v. Fit screw head
vi. Magnetic tip
vii. Ergonomic
viii. Resist corrosion/insulated handle
b. Unintended Uses
i. Pry bar
ii. Hammer
iii. Chisel
iv. Ice pick

v.
vi.
vii.
viii.
ix.
x.

Ignition
Weapon
Scraper
Backscratcher
Shear pin
Electrical jumper

Gage R&R
Repeatability & Reproducibility
Statistical Sampling
o Intro
Dodge/Romig 1920s
Inspcet
100%
0%
Somewhere in between
Popular during the war years
Faded during the 60s
o Sampling Plans
Represented by 3 numbers
N= Sample Size
C= Accept Number
R= Reject Number
Example
N=125
(take 125 parts and inspect completely)
C=3 (If 3 or fewer are defective, accept entire batch)
R=4 (If 4 or greater are defective, reject entire batch)
o Different plans for attribute data and variable data
Sample Plan
Batch of 10,000
General inspection level II
Acceptable Quality Limit = 0.15%
Find SSC on table 1 (SSC=L)
Normal

Tightened

Reduced

Single
Double
Multiple
AQL
Acceptance Quality Limit
Rejected batches are perfectly sorted
Switching rules are followed
Long term result, nothing about the batch you are looking
at

Over long term, sorting many batches, the average level

of quality will be better than (lower than) AQL.

Operating Characteristic Curves (OC curves)

o Graph
o X-Axis = P = proportion that might be bad in a batch
o Y-Axis = probability of acceptance
o Based on Binomial/Poisson
o Error moves us from ideal
Sampling error
Measurement Error
o Assume binomial applies
Two types of risk
o Alpha
Type 1 (Producer)
o Beta
Type 2 (Consumer)
I.
APQP, Control Plan
a. Intro
i. Plan and Define
ii. Product Design and Development
1. Prototype, control plan
iii. Process Design Development
1. Pre-Launch Control Plan
iv. Product and Process Validation
1. Production Control Plan
v. Feedback, Assessment, Corrective Action
1. Using TNF Control Plan
Reduced Variation
a. Customer Satisfaction
b. Delivery and Service
b. Control Plan
i. Engineering Document
ii. Systematic
iii. Plan for Controlling:
1. Process
2. Product
iv. Be careful how much process is revealed in Control Plan
II.
Analysis of Variance
a. Intro
i. Hypothesis Test
ii. Different Between Means, compares to variability
iii. ANOVA compares 2 STDEV more dat sets

b. Steps

i. State Original Question

ii. State Risk (.05)
iii. State Hypothesis
1. Ho: They are the same
2. Ha: Different in some way