9780130490360

This "mathematics-friendly" volume introduces readers to basic concepts and applications of Statistical Process Control (SPC). Readers get a solid foundation in control chartsincluding setting scales, charting, interpreting, and analyzing process capability. Problem-solving techniques are emphasized, and all learning is linked to the implementation of SPC in the workplace.The volume offers an introduction to quality concepts and statistical process control, quality issues, variation and statistics, an introduction to tables, charts, and graphs, probability and the normal distribution, control charts, variables charts for limited data, attributes control charts, problem solving, gauge capability and acceptance sampling.For quality control trainers and quality management/improvement teams.

Preface

xiii

1 Introduction to Quality Concepts and Statistical Process Control

1

(16)

1.1 What Is Quality?

1

(2)

1.2 Definitions of Quality

3

(1)

1.3 The Need for SPC

4

(1)

1.4 Prevention Versus Detection

5

(3)

1.5 SPC Goals

8

(1)

1.6 The Basic Tools for SPC

9

(1)

1.7 Statistical Process Control Techniques

9

(2)

1.8 Applying SPC to an Existing Manufacturing Process

11

(2)

1.9 Designed Experiments

13

(1)

1.10 The Quality Toolbox

14

(3)

2 Striving for Quality: Management's Problem and Management's Solution

17

(30)

2.1 Management's Problem

17

(1)

2.2 Management's Dilemma

18

(1)

2.3 Leadership by Management

19

(1)

2.4 Deming's Contribution to Quality

20

(2)

2.5 Deming's 14 Points for Management

22

(6)

2.6 Deming's Seven Deadly Diseases

28

(1)

2.7 Crosby's Approach

29

(5)

Symptoms of Trouble

30

(1)

Crosby's Four Absolutes of Quality

31

(1)

Crosby's 14 Steps to Quality Improvement

32

(2)

2.8 A Comparison of Deming's 14 Points and Crosby's 14 Steps

34

(1)

2.9 Which Way to Top Quality?

34

(2)

2.10 Pitfalls in the Quest for Quality

36

(1)

2.11 Total Quality Management (TQM)

37

(2)

2.12 The Malcolm Baldrige National Quality Award

39

(2)

2.13 Total Customer Satisfaction

41

(2)

2.14 150-9000

43

(2)

2.15 The Service Sector

45

(2)

3 Introduction to Variation and Statistics

47

(36)

3.1 Measurement Concepts

47

(4)

Measurement Error

48

(1)

Round-off Rules

49

(2)

3.2 Special-Cause and Common-Cause Variation

51

(1)

3.3 The Variation Concepts

52

(3)

3.4 Distributions and SPC Goals

55

(2)

3.5 Basic Statistical Concepts

57

(17)

Data Collection

60

(1)

Data Organization

61

(1)

Measures of the Center of a Distribution

61

(7)

Measures of the Spread

68

(6)

3.6 Distributions and 3 Standard Deviations

74

(9)

The Histogram

77

(6)

4 Organization of Data: Introduction to Tables, Charts, and Graphs

83

(46)

4.1 Stemplots

83

(4)

4.2 Frequency Distributions and Tally Charts

87

(7)

4.3 Histograms

94

(8)

Histogram Analysis Examples: Shape Interpretation

98

(4)

4.4 Pareto Charts

102

(4)

4.5 Flowcharts

106

(5)

4.6 Storyboards

111

(1)

4.7 The Cause-and-Effect Diagram

112

(4)

4.8 Checksheets

116

(1)

4.9 Scatterplots

116

(13)

5 Introduction to Probability and the Normal Probability Distribution

129

(60)

5.1 Probability

129

(2)

5.2 Compound Probability

131

(6)

The "Or" Probability

131

(3)

"And" Probabilities

134

(2)

Adjusting the "And" Rule

136

(1)

5.3 Counting with Permutations and Combinations

137

(8)

The Number of Ways

137

(1)

Permutations, PN,n

138

(1)

Factorials

139

(1)

The Mississippi Problem

140

(1)

The Two-Letter Word Problem

141

(2)

Combinations

143

(2)

5.4 The Binomial Probability Distribution

145

(4)

The Simple Random Sample

149

(1)

5.5 The Hypergeometris Probability Distribution

149

(4)

5.6 Probability Distributions

153

(5)

5.7 The Normal Probability Distribution

158

(22)

Area Under a Normal Curve

162

(5)

Other Normal Curve Tables

167

(13)

5.8 The Application of the Central Limit Theorem

180

(9)

6 Introduction to Control Charts

189

(74)

6.1 The Control Chart Concept

189

(4)

Variables and Attributes

190

(3)

6.2 Preparation for Control Charting

193

(3)

Management Direction

193

(1)

Planning

193

(1)

Chart Commentary

193

(1)

Gauge Capability

194

(1)

Sampling Plan Preparation

194

(2)

6.3 Control Charts and Run Charts

196

(1)

The Run Chart

196

(1)

6.4 The Basic x and R Chart

197

(13)

6.5 The x and R Chart Procedure

210

(18)

Action Procedures

216

(12)

6.6 The Continuation Control Chart

228

(1)

6.7 The Capability Analysis

229

(24)

Calculating the Capability Ratio

235

(1)

The Capability Index

236

(17)

6.8 Six Sigma

253

(10)

7 Additional Control Charts for Variables

263

(64)

7.1 The Median and Range Chart (x and R)

263

(16)

The and R Chart Procedure

263

(16)

7.2 The z and s Chart

279

(13)

7.3 Coding Data

292

(11)

7.4 A Modified x and R Chart for Small Sets of Data

303

(3)

7.5 The Nominal x and R Chart

306

(5)

7.6 The Transformation x and R Chart

311

(5)

The Transformation Formulas

311

(1)

The Transformation x and R Procedure

312

(3)

Chart Analysis

315

(1)

7.7 Control Chart Selection

316

(11)

8 Variables Charts for Limited Data

327

(34)

8.1 Precontrol or Rainbow Charts

328

(4)

The Precontrol Procedure

328

(1)

Calculating Zones

329

(3)

8.2 A Compound Probability Application

332

(1)

8.3 Modified Precontrol for Tight Control

333

(6)

8.4 Charts for Individual Measurements

339

(22)

The Run Chart

339

(1)

The x and MR Chart

340

(1)

Procedure for the Individual and Moving Range Chart

341

(20)

9 Attributes Control Charts

361

(36)

9.1 The Four Types of Attributes Charts

362

(1)

The p Chart

362

(1)

The np Chart

362

(1)

The c Chart

362

(1)

The u Chart

362

(1)

Applications of the Charts

362

(1)

9.2 The p Chart

363

(11)

Preparation for the p Chart

363

(1)

The p Chart Procedure

364

(10)

9.3 The np Chart

374

(5)

9.4 The c Chart

379

(4)

9.5 The u Chart

383

(4)

9.6 SPC Applied to the Learning Process

387

(3)

9.7 Technology in SPC

390

(7)

10 Interpreting Control Charts

397

(46)

10.1 The Random Distribution of Points

399

(1)

10.2 Freaks

400

(3)

10.3 Binomial Distribution Applications

403

(5)

10.4 Freak Patterns

408

(5)

10.5 Shifts

413

(5)

10.6 Runs and Trends

418

(4)

10.7 Time and Control Chart Patterns

422

(1)

10.8 Cycles

423

(2)

10.9 Grouping

425

(3)

10.10 Instability

428

(1)

10.11 Stable Mixtures

429

(1)

10.12 Stratification

430

(6)

10.13 Using Control Chart Patterns in Problem Solving

436

(7)

11 Problem Solving

443

(42)

11.1 The Problem-Solving Sequence

443

(2)

11.2 Teamwork for Problem Solving

445

(3)

11.3 Brainstorming

448

(2)

11.4 Using Problem-Solving Tools

450

(24)

Histograms for Problem Solving

451

(9)

Verifying Vendor Quality

460

(14)

11.5 Mistake Proofing

474

(2)

11.6 Problem Solving in Management

476

(3)

11.7 JIT (Just-in-Time)

479

(1)

11.8 Problem Solving in the Classroom

480

(5)

12 Gauge Capability

485

(28)

12.1 Preparations for a Gauge Capability Study

487

(1)

12.2 The Gauge Capability Procedure

487

(14)

12.3 Analysis of R and R with Accuracy and Stability: Maximum Possible Deflection

501

(5)

12.4 The Elimination of Gauge Variation from Process Variation

506

(3)

12.5 Indecisive Gauge Readings

509

(4)

13 Acceptance Sampling

513

(44)

13.1 The Sampling Dilemma

514

(7)

13.2 Random Sampling

521

(1)

13.3 Operating Characteristic Curves

522

(12)

Selecting the Best OC Curve

532

(1)

Selecting the AOL

533

(1)

13.4 The Average Outgoing Quality Curve

534

(3)

13.5 MLT-STD-105D for Inspection by Attributes

537

(13)

13.6 The Average Proportion Defective

550

(5)

13.7 Vendor Certification and Control Chart Monitoring

555

(2)

A Basic Math Concepts and Probability

557

(16)

A.1 Signed Numbers

557

(5)

Operations with Signed Numbers

558

(1)

Addition Rules

558

(2)

Subtraction

560

(1)

Multiplication and Division

561

(1)

A.2 Variables

562

(5)

Operations

563

(1)

Addition

563

(1)

Subtraction

563

(1)

Multiplication

564

(1)

Division

564

(1)

Powers

564

(2)

Roots

566

(1)

A.3 Order of Operations

567

(2)

A.4 Inequalities

569

(2)

A.5 Using the Statistical Calculator

571

(2)

B Charts and Tables

573

(14)

B.1 Formulas and Constants for Control Charts

573

(6)

Average and Range Charts: x and R

573

(1)

Median and Range Charts: x and R

574

(1)

Average and Standard Deviation: and s

575

(1)

Individual Measurement and Moving Range: x and MR

575

(1)

Attributes Charts

576

(3)

B.2 The G Chart

579

(1)

B.3 The Normal Distribution Table (Tail Area)

580

(2)

B.4 The Normal Distribution Table (Center Area)

582

(2)

B.5 The Normal Distribution Table (Left Area)

584

(2)

B.6 Process Capability

586

(1)

C Glossary of Symbols

587

(2)

D Lab Exercises

589

(16)

Answers to Exercises

605

(42)

Index

647

What is included with this book?

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.

NEED Statistical process control (SPC) is not a new topic in industry: It has been used off and on since its development in the 1920s. However, since the 1970s it has become an extremely important tool. A new economic age has developed in which the demand for quality is increasing, with a resulting global competition among companies striving to provide that quality. The detection system of final inspection, a costly method of quality control, is giving way to a prevention system that uses in-process inspection and SPC to build quality into a process. This change requires extensive training in SPC. Also, for the most effective application of SPC, management must coordinate a team effort in which everyone in the workforce can contribute meaningfully to the quality effort. PURPOSE This book was written to achieve the following goals: To describe basic statistical concepts To present a management philosophy for successful application of statistical process control To give the student a solid foundation on control charts: setting scales, charting, interpreting, and analyzing process capability To teach the student the quality concepts and problem-solving techniques associated with statistical process control To provide a readable source of SPC topics that the student can refer to as the on-the-job need arises FLEXIBILITY This book is designed for use in two-year and four-year colleges, technical colleges, and industry. The order of the chapters features a low-level mathematics approach so that anyone with a basic algebra background can learn the control chart concepts in Chapters 1 through 10 and the problem-solving concepts in Chapter 11. The book is mathematics-friendly: Only the needed mathematics is presented. The mathematics knowledge that is required for each topic is reviewed at the introduction of the topic. The entire book contains enough material for a three-credit-hour course. The mathematics; prerequisite for someone studying the entire book should be elementary algebra. The recommended sequence for college is Chapter 1 through 13, with the basic algebra in Appendix A reviewed at the beginning of Chapter 3. One possible variation in the sequence would be to teach Chapter 10 after Chapter 5. Then all of the out-of-control patterns would be available for analyzing the control charts presented in Chapters 6 through 9. The book sequence introduces a few basic out-of-control patterns for use in the presentation of control charts, followed by a more comprehensive analysis after all the control charts have been introduced. The recommended sequence for industry is Chapters 1 through 11. Chapters 12 and 13 are more job-specific and may be taught to particular groups. The basic algebra in Appendix A can be taught at the beginning of Chapter 3. EXAMPLES, ILLUSTRATIONS, AND LABS The examples, illustrations, and labs have been carefully chosen to provide a thorough understanding of the concepts involved. A detailed, step-by-step format has been used throughout to provide a pattern that can be used effectively, both for the immediate problems and for future reference. The examples and labs feature worksheets and control charts to be filled in by the student and completed worksheets and charts for checking results. Control chart masters are included at the end of the Instructor''s Manual. The text features: Chapter objectives Boxed formulas 18 case studies 165 worked examples, many with step-by-step procedures and two, three, or four step charts and diagrams More than 300 exercises Answers to the odd-numbered exercises A comprehensive lab exercise for each chapter LAB EXERCISES Comprehensive lab exercises for each chapter are included in Appendix D. They are designed to give the student a hands-on experience with the concepts that are introduced in the chapter. The lab exercises may be done in "class with supervisory assistance or they can be assigned as group projects. INSTRUCTOR''S MANUAL An Instructor''s Manual is available that contains solutions to all even-numbered exercises, solutions and/or suggestions for the lab exercises, and chart masters for overheads, class assignments, and/or tests.

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Statistical Process Control and Quality Improvement

Statistical Process Control and Quality Improvement

0130490369

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