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Quality Technician's Handbook
ISBN: 9780137474523 | 0137474520
Edition: 2ndFormat: Hardcover
Publisher: Prentice Hall Professional Technical Reference
Pub. Date: 10/1/1992
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An ASQ best-seller, this volume covers a variety of the basic skills that contribute to ongoing quality at the technician level. It is now one of the primary reference books used by people taking the ASQ Certification Exams. The volume provides an introduction to quality, and examines total quality management, quality costs and audits, inspection systems and planning, reading engineering drawings, geometric dimensioning and tolerancing, graphical inspection analysis, common measuring tools and measurements, plate inspection methods, special measuring equipment and techniques, lot-by-lot acceptance sampling plans, statistical process control and shop mathematics. For Quality Engineers, Quality Technicians and Inspectors.
| Introduction to Quality | p. 1 |
| The Quality Organization | p. 2 |
| Quality Systems | p. 2 |
| Quality and Communication | p. 7 |
| Motivation (Human Factors) and Quality | p. 7 |
| Review Questions | p. 9 |
| Total Quality Management | p. 12 |
| Quality Functions | p. 13 |
| Responsibility for Quality | p. 14 |
| TQM Tools | p. 25 |
| A Sy... MORE | p. 33 |
| Management Involvement and Commitment | p. 34 |
| Metrics | p. 35 |
| Problem Solving | p. 36 |
| Summary | p. 36 |
| Review Questions | p. 37 |
| Quality Costs | p. 41 |
| Categories of Quality Costs | p. 41 |
| Quality Cost Relationships | p. 42 |
| Pareto's Law and Quality Costs | p. 43 |
| Graphs, Charts, and Quality Costs | p. 45 |
| Hidden Quality Costs | p. 47 |
| Prevention: The Return on Quality Investment | p. 47 |
| Quality Cost Reporting | p. 48 |
| Quality Cost System Results | p. 50 |
| Review Questions | p. 51 |
| Quality Audits | p. 53 |
| Why Audit? | p. 53 |
| Key Steps of the Auditing Process | p. 54 |
| Audit Findings and Observations | p. 54 |
| Types of Quality Audits | p. 54 |
| Quality System Audits | p. 55 |
| Audit Approaches and Purposes | p. 55 |
| Auditors and Audit Teams | p. 56 |
| Planning the Audit | p. 58 |
| Conducting the Audit | p. 59 |
| Audit Reporting | p. 61 |
| Corrective Action | p. 62 |
| Closing the Audit | p. 62 |
| Review Questions | p. 63 |
| Inspection Systems and Planning | p. 66 |
| Inspection Systems | p. 66 |
| Inspection Points | p. 67 |
| Inspection Personnel | p. 69 |
| Inspection Planning | p. 69 |
| Review Questions | p. 82 |
| Reading Engineering Drawings | p. 85 |
| Lines on an Engineering Drawing | p. 85 |
| Orthographic Projection Views | p. 89 |
| Auxiliary Views | p. 91 |
| Change Block, Notes, and Tabular Dimensions | p. 95 |
| The Title Block | p. 97 |
| Rules to Follow When Using Engineering Drawings | p. 99 |
| Tolerances | p. 100 |
| Allowances and Fits | p. 101 |
| Threads (Nomenclature) | p. 103 |
| Specifying Screw Threads | p. 105 |
| Chamfers | p. 106 |
| Additional Visualization Practice | p. 107 |
| Review Questions | p. 111 |
| Geometric Dimensioning and Tolerancing | p. 114 |
| Comparison of the Standards | p. 116 |
| Other Drawing Symbols | p. 116 |
| The Dimension Origin Symbol | p. 116 |
| Maximum Material Condition--Least Material Condition | p. 121 |
| The Virtual Condition | p. 123 |
| General Rules for ASME Y14.5M-1994 Tolerancing | p. 125 |
| Inspecting Size Tolerances per ASME Y14.5 Rule 1 | p. 126 |
| Datums | p. 127 |
| Datum Targets | p. 130 |
| How to Contact Feature Datums | p. 133 |
| Coordinate Method of Positioning Features | p. 136 |
| Position Tolerancing | p. 137 |
| When Features Are Out of Position Tolerance | p. 142 |
| Understanding Bonus Tolerancing | p. 147 |
| Additional Tolerance from Size Datums | p. 148 |
| Chain, Baseline, and Direct Dimensioning | p. 149 |
| Composite Position Tolerances | p. 150 |
| Position Tolerance Stated at LMC | p. 151 |
| Zero Position Tolerance at MMC | p. 152 |
| Bidirectional Position Tolerances | p. 154 |
| Position: Fixed and Floating Fastener Cases | p. 156 |
| Projected Tolerance Zones | p. 158 |
| Functional Gages | p. 160 |
| The Chain Line | p. 163 |
| Changes in the Geometric Tolerancing Standard | p. 165 |
| Review Questions | p. 165 |
| Graphical Inspection Analysis | p. 171 |
| Geometric Tolerancing Principles | p. 171 |
| Graphical Inspection Analysis Procedure | p. 180 |
| Work Problems | p. 190 |
| Graphical Inspection Analysis Advantages | p. 194 |
| Computer Inspection Analysis | p. 198 |
| Review Questions | p. 199 |
| Common Measuring Tools and Measurements | p. 201 |
| Dimensional Measurement | p. 201 |
| Measuring Tools | p. 201 |
| Measurements and Accuracy | p. 203 |
| Types of Measurement Errors | p. 205 |
| The Steel Rule | p. 205 |
| Spring Calipers | p. 207 |
| Gage Blocks | p. 208 |
| Mechanical Indicators | p. 211 |
| Cosine Error in Indicators | p. 216 |
| TIR, FIR, and FIM | p. 218 |
| Dial Indicating Gages | p. 219 |
| Micrometers | p. 230 |
| Vernier Instruments | p. 242 |
| Telescoping Gages | p. 245 |
| Small Hole Gages | p. 249 |
| Attribute Gages | p. 249 |
| Radius Gages | p. 256 |
| Tapered (Adjustable) Parallels | p. 257 |
| Centerline Attachments | p. 260 |
| Mechanical Comparators | p. 263 |
| Measuring and Gaging Internal Threads | p. 267 |
| Measuring and Gaging External Threads | p. 268 |
| Measuring Threads: The Three-Wire Method | p. 270 |
| Basic Calibration Techniques | p. 273 |
| Review Questions | p. 274 |
| Surface Plate Inspection Methods | p. 279 |
| Surface Plates | p. 279 |
| Fixed Parallels | p. 284 |
| Care of Surface Plates | p. 285 |
| Surface Gages | p. 286 |
| Possible Sources of Errors in Measurement | p. 288 |
| Making Linear Measurements Using the Transfer Method or the Direct-Reading Method | p. 289 |
| Centerline Measurement of Features | p. 292 |
| Parallelism Measurement | p. 294 |
| Flatness Measurement | p. 298 |
| Concentricity Measurement | p. 300 |
| Runout Tolerances | p. 303 |
| Perpendicularity Measurement | p. 307 |
| Coaxiality Measurement (Using Position Tolerance) | p. 309 |
| Angularity Measurement: Angularity versus Simple Angles | p. 311 |
| Symmetry | p. 315 |
| Straightness (of an Axis) | p. 317 |
| Straightness Measurement: Straightness of Surface Elements | p. 319 |
| Using Profile Tolerances for Coplanarity | p. 321 |
| 1-2-3 Blocks | p. 322 |
| Review Questions | p. 324 |
| Special Measuring Equipment and Techniques | p. 328 |
| Electronic Measuring Equipment | p. 328 |
| Special Measuring Devices | p. 332 |
| Flatness Measurement (Using Optical Flats) | p. 336 |
| Measuring Surface Finish | p. 341 |
| Pneumatic Comparators (Air Gages) | p. 349 |
| Circularity (Roundness) Measurement | p. 352 |
| Cylindricity | p. 355 |
| Free State Variation | p. 357 |
| Optical Comparators (Profile Tolerances) | p. 359 |
| Profile Tolerances per ASME Y14.5M-1994 | p. 363 |
| Coordinate Measuring Machines | p. 367 |
| Torque Measurement | p. 372 |
| Hardness Testing | p. 374 |
| Review Questions | p. 380 |
| Lot-by-Lot Acceptance Sampling Plans | p. 384 |
| Basic Probability | p. 384 |
| Sample Statistics versus Population Parameters | p. 388 |
| Probability Distributions for Attributes | p. 389 |
| Relationships between Sampling and 100 Percent Inspection | p. 393 |
| Lot-by-Lot Acceptance Sampling versus Process Control Sampling | p. 395 |
| Random Sampling | p. 396 |
| Using ANSI/ASQC Z1.4 for Sampling Inspection | p. 399 |
| Introduction to Dodge-Romig Sampling Tables | p. 405 |
| ANSI/ASQC Z1.9 Variables Sampling Tables | p. 406 |
| Operating Characteristic (OC) Curves | p. 418 |
| Review Questions | p. 419 |
| Statistical Process Control | p. 423 |
| Objectives of SPC | p. 423 |
| Tools for Process Control | p. 424 |
| The Importance of Distribution | p. 425 |
| Measures of Central Tendency | p. 429 |
| Measures of Dispersion (Variation) | p. 433 |
| Computing the Average, Range, and Standard Deviation with Negative Numbers in the Data | p. 436 |
| Definition of a Process in Control | p. 439 |
| Control Limits versus Specification Limits | p. 440 |
| Table for the Initial Selection of Subgroup Sizes and Intervals | p. 440 |
| Various Plotting Errors to Avoid | p. 442 |
| How Measurement Errors Affect Charts | p. 442 |
| Importance of Rational Subgroups | p. 443 |
| How Calculation Errors Affect Charts | p. 444 |
| Guidelines for Starting an Average and Range Control Chart | p. 444 |
| Average and Sigma Charts | p. 449 |
| Median Control Charts | p. 452 |
| Control Charts for Individuals and Moving Ranges | p. 454 |
| Attribute Control Charts | p. 458 |
| Interpreting Control Charts: Pattern Analysis | p. 474 |
| Process Capability | p. 479 |
| Gage Repeatability and Reproducibility Studies | p. 494 |
| Miscellaneous Topics | p. 503 |
| Review Questions | p. 504 |
| Shop Mathematics | p. 508 |
| Adding and Subtracting Fractions | p. 508 |
| Multiplying and Dividing Fractions | p. 513 |
| Working with Decimals | p. 514 |
| Adding and Subtracting Angles | p. 517 |
| Working with Equations | p. 519 |
| The Circle | p. 521 |
| Perimeters | p. 527 |
| Areas | p. 529 |
| Volumes | p. 532 |
| Solving the Right Triangle for Sides Only: The Pythagorean Theorem | p. 535 |
| Solving the Right Triangle | p. 538 |
| Memorizing the Trigonometry Formulas for the Right Triangle | p. 546 |
| Solving Oblique Triangles | p. 546 |
| Tapers | p. 550 |
| Units of Measurement | p. 556 |
| Metric or English: A Comparison | p. 556 |
| Ratios | p. 559 |
| Temperature Conversion | p. 559 |
| The Real Number Line | p. 560 |
| The Cartesian Coordinate System | p. 561 |
| Scientific Notation | p. 563 |
| Review Questions | p. 564 |
| Quality Terms and Definitions | p. 567 |
| Various Manufacturing Processes | p. 575 |
| Terms Used in Reliability | p. 579 |
| Overview of Nondestructive Evaluation Methods | p. 583 |
| Bibliography | p. 585 |
| Appendix Tables | p. 587 |
| Subject Index | p. 593 |
| Formulas Index | p. 603 |
| Table of Contents provided by Syndetics. All Rights Reserved. |
Gary K. Griffith is President of Griffith Training, a productivity and quality consulting firm in Huntington Beach, California. He is a Senior Member of the American Society for Quality (ASQ), an ASQ Certified Quality Engineer, and a Fellow of the Institute for Advancement of Engineering (IAE).
