Quality Control

(MANE 4045 )
Instructor: Dr. Sayyed Ali Hosseini
Winter 2015
Lecture #1
With many figures and definitions from Introduction To Statistical Quality Control (Douglas C. Montgomery)

What is Quality?
Meeting needs, requirements, and expectations
Ways to design and implement improvements to do things
faster, better, and cheaper
CIP: Continuous Improvement Programs (Japanese
Initiatives)

MANE4045 Quality Control

Lecture #1

Quality Definition
American Society for Quality (ASQ) defines the quality as:

The characteristics of a product or service that bear on its

ability to satisfy stated or implied needs.
and/or
A product or service free of deficiencies

MANE4045 Quality Control

Lecture #1

Dimensions of Quality
Performance (Will the product perform its intended job?)
Reliability (How often does the product fail?)
Durability (How long does the product last?)
Serviceability (How easy is it to repair the product?)
Aesthetics (What does the product look like?)
Features (What will the product do beyond the basics?)
Perceived Quality (What is the reputation of the company
selling this product?)
Conformance to standards (Is the product made exactly as
the designer intended?)

MANE4045 Quality Control

Lecture #1

Different Forms of Quality

Quality of design (consumer needs, real or perceived)
Quality of conformance (specifications)
Quality of performance (intended function, or expectations)

MANE4045 Quality Control

Lecture #1

Quality of Design
Automobile differences
Materials used in construction
Specifications of the components
Reliability of drive train components
Reliability of accessories

MANE4045 Quality Control

Lecture #1

Quality of Conformance
How well does the product conform to the specifications
required by the design?
Quality of conformance is influenced by:
Choice of manufacturing processes
Training of the workers
Supervision of the workers
Motivation of the workers
Quality-assurance procedures that were used

MANE4045 Quality Control

Lecture #1

Quality is Inversely Proportional to Variability

An example: Japanese provider vs. American provider
Transmission noise (or lack of it) is wasted energy caused by
components that dont fit precisely. In addition, imprecise
components lead to wear and tear.

MANE4045 Quality Control

Lecture #1

Quality is Inversely Proportional to Variability (Cont.)

Your customer does not see the mean of your process, he only
sees the variability around that target that you have not
removed.
MANE4045 Quality Control

Lecture #1

Lessons Learned
Quality is defined by consumers (needs, requirements, and
expectations)
Processes perform value-added activities on inputs to create
outputs
Variation is present in any natural process, no two
products/services are exactly alike
Productivity is doing something efficiently, quality focuses on
effectiveness, doing the right things
MANE4045 Quality Control

Lecture #1

10

Process (Value Added Activity)

Input
Raw materials
Components
Instructions
Information
Criteria

MANE4045 Quality Control

Value added
activity
Performed by individuals,
work groups, functions,
machines, organization

Lecture #1

Output
Products
Services
Results

11

Quality Improvement
Quality improvement is the reduction of variability in
processes and products.
Alternatively

Quality improvement is also seen as waste reduction.

MANE4045 Quality Control

Lecture #1

12

Quality Characteristics
Physical - length, weight, voltage, viscosity
Sensory - taste, appearance, color
Time Orientation - reliability, durability, serviceability

MANE4045 Quality Control

Lecture #1

13

Quality Engineering
Quality Engineering is the set of operational, managerial, and
engineering activities that a company uses to ensure that the
quality characteristics of a product are at the nominal or
required levels.

MANE4045 Quality Control

Lecture #1

14

Inherent Variability
No two products are ever identical
Slight differences in materials
Slight differences in machine settings
Slight differences in operators
Slight differences in ambient temperature during production

MANE4045 Quality Control

Lecture #1

15

Types of Data
Two types of data:
Attributes Data: discrete data, often in the form of counts
Variables Data: continuous measurements such as length,
weight
Both types will be discussed in the course

MANE4045 Quality Control

Lecture #1

16

Specifications
Quality characteristics being measured are often compared to
standards or specifications.
Desired measure for the quality characteristic
Example: Shaft and bearing
If too loose, the assembly will wobble causing wear
If too tight, the assembly can not be made, no clearance

MANE4045 Quality Control

Lecture #1

17

Specifications
Nominal or target value (Desired value for a quality characteristic)
Upper Specification Limit (USL) (Largest allowable values)
Lower Specification Limit (LSL) (smallest allowable values)
USL and LSL can be one-sided or two-sided:
One-sided (The compression strength of a Coke bottle must be greater than
a given psi value)
Two-sided (The weight of potato chips in the bag can be between 7.8 and
8.3 ounces)
MANE4045 Quality Control

Lecture #1

18

Nonconforming vs. Defective

When a component or product does not meet specifications, it
is considered to be nonconforming.
A nonconforming product is considered defective if it has one
or more nonconformities that may seriously affect the safe or
effective use of the product.
Example: A new car is purchased. A bubble in the paint on the
door is noticed.
Nonconformity yes
Defective car - no
MANE4045 Quality Control

Lecture #1

19

Evolution of Quality Principles

Artisan
Inspection
Quality Control
Statistical Quality Control
Statistical Process Control
Total Quality Management
Continuous Improvements
Six Sigma

MANE4045 Quality Control

Lecture #1

20

Inspection
Detect or find non-conformances in completed products or
services
Inspection involves measuring, examining, testing, or gauging
of one or more characteristics of a product or service

MANE4045 Quality Control

Lecture #1

21

Quality Control (QC)

Use of specifications and inspection of completed parts,
subassemblies, and products to design, produce, review,
sustain, and improve the quality of a product or service
Establish standards of product or service based on customer
needs
Ensure conformance to these standards
Taking action if there is a lack of conformance
Implementing plans to prevent future nonconformance
MANE4045 Quality Control

Lecture #1

22

Statistical Quality Control (SQC)

The use of statistical methods for production monitoring and
parts inspection
Statistical data are collected, analyzed, and interpreted to
solve problems
Monitor and control variations in product or service

MANE4045 Quality Control

Lecture #1

23

Statistical Process Control (SPC)

Proactive approach to prevent defects, defectives, and
nonconformance in product or service by applying statistical
methods to control the process
Performance indicators and statistical methods will identify
changes in process that affect product or service
Limit the variations

MANE4045 Quality Control

Lecture #1

24

Total Quality Management (TQM)

Integrate quality into all areas of operation to achieve
customer satisfaction
Long-term commitment
Involves all individuals

MANE4045 Quality Control

Lecture #1

25

Continuous Improvement (CI)

Focus on improving processes to enable companies to meet
customer satisfaction all the time
Attention to details with teamwork
Quality council, quality individuals, managers, surveys for
customers / employees

MANE4045 Quality Control

Lecture #1

26

Six Sigma
Developed by Motorola in the late 80s
To increase system reliability and reduce failure rates: DefineMeasure-Analyze-Improve-Control (DMAIC)
Involves all levels in the organization
Consider that
the two tales

provides 0.00135 in each tail, or 0.00270 in

So, in 1 million parts, 2700 would be defective

MANE4045 Quality Control

Lecture #1

27

Six Sigma

MANE4045 Quality Control

Lecture #1

28

An Example of Six Sigma vs. Three Sigma

Consider an assembly of 100 parts that must all function for
the assembly to function
.
.
.
= .
= .
Thus, about 23.7% of the products under will fail which is
not usually an acceptable situation
But, 6 results in 0.999999998 inside specs
.
= .
Or, 2 parts/billion defective (i.e., 0.2 ppm) which is much
better than

MANE4045 Quality Control

Lecture #1

29