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Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 1
Resource PersonDr. Muhammad Wasif, PMP Assistant ProfessorDepartment of Industrial and Manufacturing Engineering,NED University of Engineering and Technology.
IM 511
Statistical Quality Control
Resource Person
Dr. Muhammad Wasif, PMP
Assistant Professor
Department of Industrial and Manufacturing Engineering,
NED University of Engineering and Technology.
Communications • Computing • Services • Manufacturing • Defense & Aerospace • Medical • Automotive
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 2
Qualification
2003 – B.E. in Mechanical Engineering from NED University.
2007 – M. Engg. In Industrial & Manufacturing Engineering from NED University.
2013 – Ph.D. in Mechanical Engineering from Concordia University, Montreal (Quebec) Canada.
2016 – Project Management Professional (PMP)
Experience
2004 ‐2006 – Worked in Assembly Operations Plant of Hinopak Motors Ltd.
Developed the Vehical Inspection Department (VID) on Main Assembly Line
2008‐2012 – Research Project for the accurate manufacturing of Hypoid Gears.
2006 ‐ to date – Worked as “Lecturer” and “Asst. Professor” in IMD, NED UET.
Area Coordinator & Auditor for ISO Management.
Member, Board of Review, Quality Management Cell.
Resource Person
3© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Optimization of milling parameters for various types of fibers
reinforced composite materials (FRP) (SUPARCO, 2015).
Optimal parameters for the drilling of carbon fiber reinforced (FRP)
composite material (SUPARCO, 2015).
Influence & Impact of Vendor Performance System for Automobile
Supply Chain Industry. (Pak‐Suzuki Motors Limited, 2014).
Optimization of parameters for the plasma coating of aerospace alloys
(Pakistan Air Force – PAF, 2014,).
Processes /parameter optimization for deep‐hole drilling using
coated/un‐coated HSS drills on three different materials such as MS,
AL Alloy (AA‐2024) & Titanium. (SUPARCO, 2013).
Projects
4© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 3
Reverse Engineering of the 250cc engine of a multi‐purpose vehicle, to
be developed and manufacture in Pakistan, in collaboration with the
DICE Foundation, USA. (3 projects NED UET, DICE Foundation USA
and an entrepreneur/investor, 2015).
Study the behavior of Spring‐back of high tensile Hot Rolled Steel.
(Pak‐Suzuki Motors Limited, 2014).
Productivity increase by Optimization of Investment Casting Process.
(Precision Engineering Complex ‐ PEC, PIA, 2014).
Development of an Automatic Identification & Data Capture (AIDC)
system using Radio Frequency Identification Device (RFID) for a
Warehouse (2014).
Projects
5© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Project Management class is an open discussion forum, where students
can add their experiences or raise queries.
During discussions, resource person will act as moderator.
Punctuality of time is necessary to validate the attendance, else it will be
marked absent.
One Break will be allowed for Maghreb prayer and refreshment.
Mobile phone ringtones should be on silent.
Food, smoking and Drinks not allowed.
Submission of assignments and conduction of tests will be on prescribed
dates.
Assignments must be submitted with the “Assignment Form“ uploaded
on one‐drive.
Class Room Decorum
6© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 4
Class contact hours
Consulting hours Before and after class or by appointment
Consulting Office Room 2, Ground floor, Department of Industrial
and Manufacturing Engineering Building.
e‐mail [email protected]
Sent your information http://goo.gl/forms/JKRBxEt07h
Once form is filled, you will receive google
drive link to access the lecture slides.
Course Contact
Class Day Timings
MEM (IM) Thursday 18:00pm to 21:00pm
7© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Recommended BooksBook : Statistical Quality ControlAuthor : Douglas C. MontgomeryEdition : 6th
Publishers : Wiley & Sons
Book : Fundamentals of Quality Control And ImprovementAuthor : Amitava MitraEdition : 2nd or 3rd
Publishers : Wiley & Sons
Book : Statistical Process Control And Quality ImprovementAuthor : Gerald M. SmithEdition : 5th
Publishers : Pearson International
8© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 5
Sessional Marks
Final Examination Marks 60
Sessional Marks 40
Quiz (Mid-Term) 15
Assignments 15
Class participation 5
Attendance 5
9© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
1. Review of Probability & Statistics,
2. Probability Distributions,
3. Hypothesis Testing (One‐Tail and Two‐Tail Tests),
4. Sampling Distributions,
5. Quality Control & Assurance,
6. Causes of Variation,
7. Control Charts (for attributes and variables),
8. EWMA Chart and CUSUM Chart,
9. Metrology & Gauging,
10. Gauge Capability Analysis,
11. Gauge Repeatability and Reproducibility,
12. Process Capability Indices,
13. Acceptance Sampling (for attributes and variables).
Course Contents
10© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 6
Develop clear understanding of the use of modern
statistical methods for quality control and improvement
To develop the knowledge of principles and the basis for
applying them in a variety of situations (mostly
engineering and management)
To understand the analysis and use to computer‐aided
tool for the quality control and imrpovement
Course Objectives
11© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Resource PersonDr. Muhammad Wasif, PMPAssistant ProfessorDepartment of Industrial and Manufacturing Engineering,NED University of Engineering and Technology.
Topic # 1
Introduction to Statistical Quality Control
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 7
Statistics and Quality
Use of statistical methods to improvethe quality of the products
How : to Monitor and Control a Process
Statistics: is the study of the Collection,Organization, Analysis, Interpretation,and Presentation of Quantitative data
Manufactured goods: such asautomobiles, computers, and clothing,appliances
Services such as the generation anddistribution of electrical energy, publictransportation, banking, retailing, andhealth care.
Statistical Quality Control
14© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 8
What is quality ?
Fitness for use: conformance‐to‐specifications (Juran)
Quality of design: various grades or levels of quality
Safe and smooth transportation but with various size, appointments,
appearance, and performance
E.g. Toyota, Lexus, Hino are different brand of Toyota
Group.
Quality of conformance: how well the product conforms to
the specifications required by the design (Crosby)
This definition does not address “fit‐for use” by the
customer
Definition of Quality
15© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
What is quality ?
Quality is inversely proportional to variability
A comparative study of a transmission that was manufactured in a domestic
plant and by a Japanese supplier
Modern Definition of Quality
16© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Warranty costs for transmissions Distributions of criticaldimensions for transmissions.
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 9
Dimensions of Quality
17© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Dimensions of Quality (Garvin 1987)
18© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Dimension Meaning & Example
Performance Primary Product Characteristics, such as the BRIGHTBNESS of the Picture.(will the product do the intended job?)
Reliability Consistency of Performance over Time, average time for the unit to fail.(How often does the product fail?)
Durability Useful life, includes Repair.(How long does the product last?)
Serviceability Resolution of problems and Complaints, ease of repair.(How easy is it to repair the product?)
Aesthetic Sensory Characteristics, such as EXTERIOR FINISH.(What does the product look like?)
Features Secondary Characteristic, added Features, such as REMOTE CONTROL.(What does the product do?)
Perceived Quality (Reputation)
Past Performance and other Intangibles such as being Ranked 1st.(What is the reputation of the company or its products?)
Conformance to Standards
Meeting Specifications or Industry Standards, Workmanship.(Is the product made exactly as the designer intended?)
Response Human‐to‐human interface, such as Courtesy of the dealer.
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 10
It is the reduction of variability in
processes and products
Excessive variability in process performance
often results in waste.
Quality improvement is the elimination of
waste
Particularly effective in service industries,
where there may not be as many things that
can be directly measured
Quality improvement
19© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
A characteristics of products that describe the user or consumer
thinks of as quality is called quality characteristics (critical‐
to‐quality (CTQ) characteristics)
Structural (Length, Weight, Strength etc.)
Sensory ( Taste, Smell, Color etc.)
Time Oriented (Warranty, Reliability, Durability etc.)
Ethical Characteristics (Honesty, Courtesy, Friendliness etc.)
Quality Engineering Terminology
20© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 11
Quality Characteristics fall into TWO broad classes;
Variables : Characteristic that are Measurable and are
expressed on a Numerical Scale are called Variables.
For example: Diameter, Length, Density, Resistance of Coil
Attributes: (Countable Characteristic) A Quality
Characteristic is said to an Attribute (Countable) if it is
classified as either Conforming of Nonconforming to a
stipulated Specification.
For example: Smell of Cologne, Color, Go/no‐go, Pass/Fail
Quality Engineering Terminology
21© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Standard or Specification: Quality characteristics are oftenevaluated relative to specifications. E.g.
In manufacturing diameter is shaft 25±0.5 means 24.5mm to 25.5mm In service maximum time at checkout counter 90seconds.
Target or nominal values: desired value for that qualitycharacteristic (25mm)
Lower specification limit (LSL): Smallest allowable value for aquality characteristic (24.5mm)
Upper specification limit (USL): Largest allowable value for aquality characteristic (25.5mm)
Non Conformity: Defect (26mm or 24.4mm)
Nonconforming Unit : Defective
Not all products containing a defect are necessarily defective
Quality Engineering Terminology
22© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 12
Quality of Design: (Should be Simple &Least Expensive) It implies that theProduct or Service must be Designed tomeet at least minimally the needs of theConsumer.
Quality of Conformance: Quality ofConformance implies that theManufactured Product or the Servicerendered must meet the Standards selectedin the Design phase.
Quality of Performance: It is concernedwith how well the Product Functions orService performs when put to use.
Quality Engineering Terminology
23© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
QUALITYQUALITY
Quality of Performance
Quality of Performance
Quality of Design
Quality of Design
Quality of Conformance
Quality of Conformance
Voice Of Customer (VoC): The ʺvoice ofthe customerʺ is the term to describe thestated and unstated customer needs orrequirements.
Voice Of Process (VoP): It results of thehistorical performance of the process (orsystem). The VoP details, what the processis capable of producing.
Concurrent engineering: a team approachto design, with specialists inmanufacturing, quality engineering, andother disciplines working together with theproduct designer at the earliest stages of theproduct design process.
Quality Engineering Terminology
24© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 13
Quality Circle: It is typically an informal group of people
that consists of Operators, Supervisors, Managers, and so on,
who get together to improve ways to make the product or
deliver the service.
Quality Engineering Terminology
25© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Quality Engineering Terminology
26© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
QUALITY CONTROL
Quality Control may generally bedefined as a system to maintain a desired level in a
Product or Service. (Amitva Mitra)
A System that is used to maintain a desired level of Quality in a Product or Service.
(Amitva Mitra)
QC is the Operational Techniques & Activities which sustain a Quality of Product or Service that will given needs.
(William J. Kalorik)
QUALITY ASSURANCE
All those Planned or Systematic Actions necessary to provide confidences that a Product or Service Satisfy given needs.
(Amitva Mitra)
QUALITY ENGINEERING
Quality Engineering is the Set of Operational, Managerial & Engineering Activities that a company uses to ensure that a Quality Characteristics of a Product are at the
Nominal or Required level. (Amitva Mitra)
QUALITY PLANNING
Is a Strategic Activity, and it is just an vital to an organization’s long term business success as the product development Plan, the Financial Plan, the Marketing Plan , and the Plan for
utilization of Human Resources.(Douglas C. Montgomery)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 14
Quality Engineering Terminology
27© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
History of Quality Improvement
28© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 15
Statistical Methods for Quality Control and Improvement
29© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
ProcessInput
Raw Material,Components,
Sub-assemblies,and/or
Information
OutputY=Quality
Characteristics(CTQs)
Controllable Inputs:Temperature, Pressure
X1, X2, . . . . . . , Xn
Uncontrollable Inputs:Environmental Factors,
Properties of Raw Material provided by External Customer
Z1, Z2, . . . . . . , Zn
Measurement Evaluation Monitoring & Control
Product
[Production Process Inputs and Outputs]
Process is a series of activities that takes an Input, adds value to it and produces an Output for a Customer
Statistical process control (SPC):
Control charts, plus other problem‐solving tools
Useful in monitoring processes, reducing variabilitythrough elimination of assignable causes
On‐line technique
Designed experiments (DOE)
Discovering the key factors that influence processperformance
Process optimization
Off‐line technique
Acceptance Sampling
It is the Inspection and classification of a sample of unitsselected at random from a larger batch or lot and theultimate decision about disposition of the lot, usuallyoccurs at two points: incoming raw material, or finalproduction.
Statistical Methods
30© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
ProcessProcessInput Output
Search for input that vary the output
ProcessProcessInput Output
Input is optimized for desired output
ProcessProcessInput Output
Input is sampled to analyzed for desired output
scrap
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 16
Statistical Methods
31© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Quality Philosophy & Management Strategies
32© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Walter A. Shewhart (1891-1967) : (Some times referred as Father of SQC)• worked at the Hawthorne Plant of Western Electric, where he developed
(1924) and used Control Charts.• He describes the basic Principles of SQC in his book “Economic Control of
Quality of Manufactured Product (1931).• He was the first honorary member of ASQ.
W. Edward Deming: • Developed a list of 14 Points.• Deming Cycle (PDSA Cycle)• Deming's Seven Deadly Diseases of Management
Joseph M. Juran (1904-2008): • Developed the Juran Trilogy.• Deming and Juran worked in both the US and Japan to help businesses
to understand the importance of Continuous Improvement.
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 17
Quality Philosophy & Management Strategies
33© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Philip B. Crosby:•Originated the Zero Defect Concept.• Was an ASQ honorary member and Past President.
Armand V. Feigenbaum : • Originated the concept of Total Quality Control.• He is an ASQ honorary member and served as ASQ President for Two
consecutive terms.
Kaoru Ishikawa: • Developed Cause and Effect Diagram.• He worked with Deming through the Union of Japanese Scientists and
Engineers (JUSE)Genichi Taguchi:
• Taught that any departure from Nominal or Target value for a characteristicrepresents a Loss to Society.
• He is also popularized the use Fractional Factorial Experiments.
1. Lack of constancy of purpose
2. Emphasis on short‐term profits
3. Performance evaluation, merit rating, annual
reviews
4. Mobility of management
5. Running a company on visible figures alone
6. Excessive medical costs for employee health
care
7. Excessive costs of warrantees
Deming’s Deadly Diseases
34© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 18
Shewart Cycle (PDCA cycle)
35© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Shewart Cycle (PDCA cycle)
36© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Other Short Topics just define them:
TQM (Total Quality Management)
Deming/Juran Value engineeringZero defect philosphy
Quality Systems & Standards ISO Generic standard for Quality systems
Six Sigma Motorola InvariabilityMoving mean
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 19
Quality Systems and Standards
37© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Quality Systems and Standards
38© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
• The ISO certification process focuses heavily on quality assurance, without sufficient weight given to quality planning and quality control and improvement
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 20
Six Sigma
39© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Use of statistics & other analytical tools has grown steadily for
over 80 years
Statistical quality control (origins in 1920, explosive growth
during WW II, 1950s)
Operations research (1940s)
FDA, EPA in the 1970’s
TQM (Total Quality Management) movement in the 1980’s
Reengineering of business processes (late 1980’s)
Six‐Sigma (origins at Motorola in 1987, expanded impact
during 1990s to present)
Six Sigma
40© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
A process is an organized sequence of activities that produces an
output that adds value to the organization
All work is performed in (interconnected) processes
Easy to see in some situations (manufacturing)
Harder in others
Any process can be improved
An organized approach to improvement is necessary
The process focus is essential to Six Sigma
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 21
Six Sigma
41© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Six Sigma Focus
42© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Initially in manufacturing
Commercial applications
Banking
Finance
Public sector
Services
DFSS – Design for Six Sigma
Only so much improvement can be wrung out of an existing
system
New process design
New product design (engineering)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 22
Six Sigma Focus
43© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Initially in manufacturing
Commercial applications
Banking
Finance
Public sector
Services
DFSS – Design for Six Sigma
Only so much improvement can be wrung out of an existing
system
New process design
New product design (engineering)
Six Sigma
44© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
A disciplined and analytical approach to process and productimprovement
Specialized roles for people; Champions, Master Black belts, BlackBelts, Green Belts
Top‐down driven (Champions from each business)
BBs and MBBs have responsibility (project definition, leadership,training/mentoring, team facilitation)
Involves a five‐step process (DMAIC) :
Define
Measure
Analyze
Improve
Control
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 23
Lean Systems
45© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Focuses on elimination of waste
Long cycle times
Long queues – in‐process inventory
Inadequate throughput
Rework
Non‐value‐added work activities
Makes use of many of the tools of operations research and
industrial engineering
Quality Cost
46© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Lecture Notes of Statistical Quality Control (IM‐511)
© Dr. Muhammad Wasif, PMP (Assistant Professor ‐ IMD, NED UET) 24
Managing Quality Cost
47© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)
Managing Quality Cost
48© Dr. Muhammad Wasif, PMP ‐ Asst. Professor (IMD ‐NED UET)