First Course in Quality Engineering

For senior-level courses in quality methodology for engineering majors. This text contains virtually all the information an engineer would need to function as a quality engineer. The author covers management methods and statistical methods of quality in an integrative manner ?  unlike other books on the subject, which focus primarily on one of the two areas of quality.  Many real world examples, drawn from the author?s consulting work, illustrate the use of quality methods. Mini projects help students understand and solve real problems. 

Table of Contents:
Preface xiii   1 Introduction to Quality 1   A Historical Overview 1 A Note about “Quality Engineering” 5 Defining Quality 7 Product Quality vs. Service Quality 8 The Total Quality System 9 Total Quality Management 11 Economics of Quality 12 Quality, Productivity, and Competitive Position 13 Quality Costs 14 A Case Study in Quality Costs 27 Success Stories 32 Cadillac Motor Car Company (Winner of the 1990 MBNQA) 32 Boeing Airlift and Tanker Programs (Winner of the 1998 MBNQA) 34 Exercises 37 Mini-Project 1.1 40 Mini-Project 1.2 41 References 42   2 Statistics for Quality 43   Variability in Populations 43 Some Definitions 44 Section I: Empirical Methods for Describing Populations 46 The Frequency Distribution 46 The Histogram 47 The Cumulative Frequency Distribution 48 Numerical Methods for Describing Populations 52 Calculating the Average and Standard Deviation 53 Other Graphical Methods 54 Stem-and-Leaf Diagram 54 Box-and-Whisker Plot 55 Other Numerical Measures 56 Measures of Location 56 Measures of Dispersion 56 Exercise in Empirical Methods 57 Section II: Mathematical Models for Describing Populations 59 Probability 59 Definition of Probability 60 Computing the Probability of an Event 60 Theorems on Probability 63 Counting the Sample Points in a Sample Space 70 Exercise in Probability 73 Probability Distributions 75 Random Variable 75 Probability Mass Function 76 Probability Density Function 78 The Cumulative Distribution Function 79 The Mean and Variance of a Distribution 80 Some Important Probability Distributions 82 The Binomial Distribution 83 The Poisson Distribution 85 The Normal Distribution 86 Distribution of the Sample Average 93 The Central Limit Theorem 94 Exercise in Probability Distributions 95 Section III: Inference of Population Quality from a Sample 96 Definitions 96 Confidence Intervals 98 CI for the of a Normal Population When Is Known 98 Interpretation of CI 99 CI for When Is Not Known 99 CI for of a Normal Population 100 Hypothesis Testing 102 Test Concerning the Mean of a Normal Population When Is Known 103 Why Place the Claim Made About a Parameter in 105 The Three Possible Alternate Hypotheses 106 Test Concerning the Mean of a Normal Population When Is Not Known 107 Test for Difference of Two Means When Are Known 108 Tests for Normality 110 Use of the Normal Probability Plot 110 Normal Probability Plot on the Computer 112 A Goodness-of-Fit Test 113 The P Value 115 Exercise in Inference Methods 116 Mini-Project 2.1 117 Mini-Project 2.2 118 References 119   3 Quality in Design 120   Planning for Quality 120 The Product Creation Cycle 120 Product Planning 122 Finding Customer Needs 122 Quality Function Deployment 126 Reliability Fundamentals 131 Product Design 140 Parameter Design 140 Design of Experiments 141 Tolerance Design 156 Failure Mode and Effect Analysis 161 Concurrent Engineering 164 Process Design 166 The Process Flow Chart 167 Process Parameter Selection: Experiments 169 Floor Plan Layout 173 Process FMEA 173 Process Control Plan 173 Other Process Plans 175 Exercises 178 Mini-Project 3.1 181 Mini-Project 3.2 181 Mini-Project 3.3 181 References 182   4 Quality in Production: Process Control–I 184   Process Control 184 The Control Charts 185 A Typical Control Chart 186 Measurement Control Charts 188 and R-Charts 189 A Few Notes About the and R-Charts 194 and S-Charts 205 Attribute Control Charts 209 The P-Chart 209 The C-chart 212 Some Special Attribute Control Charts 214 The P-Chart with Varying Sample Size 214 The nP-Chart 217 The Percent Defective Chart (100P-chart) 218 The U-Chart 218 A Few Notes About the Attribute Control Charts 221 vii.Summary of Control Charts 223 Implementing SPC on Processes 224 Process Capability 229 Capability of a Process with Measurable Output 229 Capability Indices and 229 Capability of a Process with Attribute Output 233 Measurement System Analysis 234 Properties of Instruments 234 Measurement Standards 236 Evaluating an Instrument 237 Exercises 246 Mini-Project 4.1 250 Mini-Project 4.2 250 References 251   5 Quality in Production: Process Control–II 253   Derivation of Limits 254 Limits for the 254 Limits for the R-Chart 257 Limits for the P-chart 258 Limits for the C-Chart 259 Operating Characteristics of Control Charts 259 Operating Characteristics of an 259 OC Curve of an R-Chart 262 Average Run Length 263 OC Curve of a P-Chart 266 OC Curve of a C-Chart 268 Measurement Control Charts for Special Situations 269 and R-Charts when Standards for and/or Are Given 269 Control Charts for Slow Process 274 Control Chart for Individuals (X-Chart) 274 Moving Average and MR Charts 276 The Exponentially Weighted Moving Average Chart 279 Control Charts for Short Runs 286 The DNOM Chart 287 The Standardized DNOM Chart 289 Topics in Process Capability 291 The Index 292 Confidence Interval for Capability Indices 294 Motorola’s Capability 296 Topics in Design of Experiments 300 Analysis of Variance 300 The General Design 306 Design 306 Fractional Factorials: One-Half Fractions 308 viii.Exercises 318 Mini-Project 5.1 321 Mini-Project 5.2 321 References 322   6 Managing for Quality 323   Managing Human Resources 323 Importance of Human Resources 323 Organizations 324 Quality Leadership 327 Customer Focus 329 Open Communications 331 Empowerment 332 Education and Training 334 Teamwork 339 Motivation Methods 346 Principles of Management 347 Strategic Planning for Quality 347 History of Planning 347 Making the Strategic Plan 349 Strategic Plan Deployment 351 Exercises 351 Mini-Project 6.1 351 References 351   7 Quality in Procurement 353   Importance of Quality in Supplies 353 Establishing a Good Supplier Relationship 354 Essentials of a Good Supplier Relationship 354 Single vs. Multiple Suppliers 354 Choosing a Supplier 356 Certifying a Supplier 357 Specifying the Supplies Completely 357 Auditing the Supplier 358 Supply Chain Optimization 359 Using Statistical Sampling for Acceptance 363 The Need for Sampling Inspection 363 Single Sampling Plans for Attributes 365 The Operating Characteristic Curve 365 Designing an SSP 368 Double Sampling Plans for Attributes 371 MIL-STD-105E 377 Average Outgoing Quality Limit 380 Some Notes About Sampling Plans 391 Exercises 392 References 393   8 Continuous Improvement of Quality 395   The Need for Continuous Improvement 395 The Problem-Solving Methodology 396 Deming’s PDCA Cycle 396 Juran’s Breakthrough Sequence 398 The Generic Problem-Solving Methodology 399 Quality Improvement Tools 402 Cause-and-Effect Diagram 402 Brainstorming 403 Benchmarking 404 Pareto Analysis 408 Histogram 410 Control Charts 411 Scatter Plots 412 Regression Analysis 414 Correlation Analysis 424 Exercises 428 Term Project 8.1 430 References 430   9 A System for Quality 431   The Systems Approach 431 Dr. Deming’s System 432 Long-Term Planning 433 Cultural Change 434 Prevention Orientation 434 Quality in Procurement 434 Continuous Improvement 435 Training, Education, Empowerment, and Teamwork 436 Dr. Juran’s System 440 Quality Planning 441 Quality Control 443 Quality Improvement 444 Dr. Feigenbaum’s System 447 Baldrige Award Criteria 450 Criterion 1: Leadership 452 Criterion 2: Strategic Planning 453 Criterion 3: Customer and Market Focus 454 Criterion 4: Measurement, Analysis, and Knowledge Management 454 Criterion 5: Human Resource Focus 455 Criterion 6: Process Management 456 Criterion 7: Business Results 458 ISO 9000 Quality Management Systems 459 The ISO 9000-2000 Family of Standards 459 The Eight Quality Management Principles 460 Documentation in ISO 9000 462 ISO 9001-2000 Requirements 462 Quality Management System 463 General Requirements 463 Documentation Requirements 463 Management Responsibility 464 Management Commitment 464 Customer Focus 464 Quality Policy 464 Planning 465 Responsibility, Authority and Communication 465 Management Review 465 Resource Management 466 Provision of Resources 466 Human Resources 466 Infrastructure 466 Work Environment 466 Product Realization 467 Planning of Product Realization 467 Customer-Related Process 467 Design and Development 468 Purchasing 469 Production and Service Provision 469 Control of Monitoring and Measuring Devices 471 Measurement, Analysis and Improvement 471 General 471 Monitoring and Measurement 472 Control of Nonconforming Product 472 Analysis of Data 473 Improvement 473 The Six Sigma System 474 Six Themes of Six Sigma 474 The Measure 476 The Three Strategies 477 The Two Improvement Processes 478 The Five-Step Road Map 478 The Organization for Six Sigma 481 Summary of Quality Management Systems 481 Exercises 483 Mini-Project 9.1 485 Mini-Project 9.2 485 References 485   Appendix Statistical Tables 486   Answers to Selected Exercises 496   Index 505