STAT 513/IE 530 - Spring 2017
Statistical Quality Control MWF

11:30-12:20 REC 227

12:30-1:20 REC 227

 

Instructor: Professor Tom Kuczek (kuczek AT purdue.edu)
Office: 152 HAAS, 765-494-6051
Office hours: 11-12 T-Th.  Feel free to send questions by e-mail if more convenient.                                                                                                                                                                                                                                                                                                                                                                                                               

Course Web Address:  http://www.stat.purdue.edu/~kuczek/stat513

Announcements: No Office hours Thursday April 27.

                                No class Friday, April 28. I will be in my office Friday during class time.

                                

 

TA:  11:30 : Hao Xin (xin11@purdue) office hours: Monday 2-3:30, 157D Grissom Hall.

        12:30 : Min Ren (ren80@purdue) office hours: Thursday 9:30-11, Math 541.

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                       Text: Introduction to Statistical Quality Control, Seventh Edition, Montgomery, D.C., Wiley.   

 

Grades: Grades will be determined in the following fashion. There will be two midterms. Each midterm is worth 100 points and homework will be worth 50 points. There will be a group project worth 40 points. There will be 10 points given to students who fill out the online course evaluation. Your grade will be determined out of your total of 300 points.

Exams: Exams are based primarily on lecture material and designated reading material. You are responsible for what is discussed in class. All exams are closed book, closed notes. I have created two hyperlinks to folders entitled “Older SPC Exams” and “Recent SPC Exams”. Due to the change in textbook, they can be useful on some topics but not a reliable guide for coming exams. While exam questions vary in difficulty, the answers are generally quite brief given the time constraints on the exams.

Software: You are free to use any software package you wish, but I recommend JMP. Help with statistical software packages is available at the help desk in MATH G175.  JMP, which is popular in Industry, is available in all ITaP labs and can be used remotely. JMP is also free to students. You can check out a copy from ITaP by going to STEW G31 (the location used to be in YONG). You can check out a copy overnight to load onto your laptop or desktop. It’s very good for preparing presentations. R software is open source (i.e. free) and the Program “qcc” in R will do most of the necessary control charts.

HW: HW is to be uploaded to Blackboard by 5 p.m. the date due. Note: individual homework will be graded out of 100 points (i.e. a percent). At the end of the semester they will be averaged to give an average percent score on HW, this will determine your percent of the 50 point total for HW. Late HW is ½ off.

 

Course Evaluations:

Send a copy of the form which states you have completed the course evaluation to the grader. There have been problems with evaluations sent to students going directly to their junk mail folders. Students should log on to the evaluation site by visiting www.purdue.edu/eval to fill out course evaluations.

                                                                                                                                                                                                                                                                                                                                                       Course Objectives: To become fluent in the language and techniques of modern Quality Control and its applications. While areas of application are typically thought of as being in the area of manufacturing, (including processes related to ordering, accounting, record keeping and customer satisfaction) principles of Quality management are applicable to all types of organizations. These areas include: Health Care, Service Industry, Pharmaceutical, Education (at all levels), Non-Profit, Small Business, Software Reliability, etc.

 Course Topics: 

1.       Basic concepts.

2.       Basic probability.

3.       Summarizing Data.

4.       Basic Tools (flowcharts, fishbone diagrams, Pareto charts).

5.       More Advanced Tools (process flow diagrams, Cause and Effect Matrices)

6.       FMEA: Failure Modes and Effects Analysis

7.       Shewhart Control Charts.

8.       Facts about Control Charts.

9.       Effective use of Control Charts.

10.   Control Charts for Attribute Data.

11.   Effective use of Attribute Data.

12.   Capability.

13.   Use of Control Charts for Continual Improvement.

14.   Topics for Measurement Charts.

15.   Acceptance Sampling (and why it’s a bad thing to rely on).

16.   Six Sigma and DMAIC.

17.   Experimental Design, Taguchi Methodology and Alternatives.

18.   ISO and WTO.

 

 

Schedule: This will be edited as the semester goes on since some material will change a bit.

 

Current

Week 1: Read Chapter1 and  Quality Control (Then and Now).pptx. Movie “Right First Time” will be shown in class. Read Basics of Defining Processes.ppt and 3-Measures.ppt . Background on Pareto pareto and quality.docx Montgomery ch01.ppt

 

Week 2: No class Monday January 16, MLK holiday. Read Chapter 3, a review of basics of Sampling and Probability Distributions.

·         Basic tools

·         Sampling and Quality Control.pptx

·         SPC Basic sampling distributions.pptx

·         Comments on DMAIC model in text, chapter 2.

 

Week 3: Read Chapter 3, sections 3.1 and 3.2 are important. Section 3.4.1 will be important later in the semester.  Read Chapter 4 in the text, it is a basic review of hypothesis testing and confidence intervals. Everyone should have seen this material before in a basic Statistics course. The material on Regression and ANOVA will be important later in the course. Read chapter 4.

·         PDCA Cycle.pptx

·         4-Displaying Measures.ppt

·         Montgomery slides montgomery ch03.ppt

·         Homework 1, do problems 3.9 and 3.10, due Wednesday, January 25.

·          spc ch3 E1 failure times.xls   spc ch3 E2 process yield.xls spc ch3 E3  viscosity.xls

·         Common Cause Variation.pptx

·         X-bar and R charts.pptx

·         Basic Chart Concepts.pptx

·         Diagnosing Variability Cause and Effect matrix

 

Week 4:  Read Chapter 5 in the text on basic tools and basics of Control Charts. Read chapter 6 on X-bar and R-charts.

·       Homework 2, due Wednesday, Feb. 1 of Week 4, is to make a flowchart of how you studied    for one of your most recent (and difficult) final exams. Use the flowchart symbols in your flowchart (you may do it by hand if you wish but M$ Word is easy to use). Be sure to include decision points. For example, after reviewing a topic, how you decide if further review is necessary.

·      Homework 3, problem 5.24, due Wednesday Feb. 1.

·         Common Cause Variation.pptx

·         Individuals Charts.pptx

·         https://www.youtube.com/watch?v=RMjtmsr3CqA . How does injection molding work?

·         Rational subgrouping great example on Fixed Differences

·         Rational subgrouping another example

·         SPC Montgomery ch04-1.ppt Most of topics a review of hypothesis testing.

·         One-Way ANOVA 3.21.pptx

·         Exercise 4.35 problem4_35.xls

·         SPC Montgomery ch05.ppt Introduces control charts, limits, rules and reviews basic tools.

·         FMEA Material

 

Week 5: Read Chapter 6, Control Charts for Variables. Homework 4: Problem 6.8, parts (a) and (c), problem 6.9, parts (a) and (b). Due Wednesday, Feb. 8.

·         SPC Montgomery slides ch06.ppt

·         Exercise 6_8 data.xls

·         Exercise 6_9 data.xls

·         Basics of Capability.ppt

·         Inadequate Measurement Units.pdf

·         Deming's 14 Points.pdf This the original version of Deming’s points.

·         Deming.docx Deming’s 14 points updated.

·         https://en.wikipedia.org/wiki/Total_quality_management Compare early efforts to now.

·         Stat 513IE 530 Group Project Guidelines.docx groups will be formalized this week. Presentations will begin the Monday after Spring Break.

·         http://wordprocessing.about.com/od/microsoftword2007/a/researchpapers07.htm: Good reference on how to properly cite material

 

Week 6: Read Chapter 7, Control Charts for Attributes. Homework 5: Problem 6.8 part (b) and problem 6.9 part (c), for part (c) compute both Cp and Cpk, due Wednesday Feb. 15.

·         Attributes Data.pptx

·         Attribute Charts and low defect rates.pptx

·         Effective use of Attribute Charts.pptx

·         SPC Montgomery ch07.ppt

·         SPC Exercise 5_24 solution.docx solution HW3

·         Spc chapter 6 problems.docx solution to HW 4 5

·         SPC hw solutions 7_29 7_50.docx

 

 

Week 7: Finish Attributes charts and start Measurement System Analysis, Chapter 8.

·         HW 6: Problems 7.29 and 7.50, due Wednesday, February 22.

·         metrology videos.docx

·         Data for 7_29.xls Data for 7_50.xls

·         Measurement Analysis.pptx

·         Basic and Derived Units and the Pyramid of Standards

·         Metrology again: https://www.youtube.com/watch?v=ZMByI4s-D-Y&list=PLgM5FyJb22zyL68BvEHF6Iq4famgsIagf

·         Friday, review of topics for exam.

 

Week 8: Chapter 8 on measurement analysis.

·         Exam I, Tuesday Feb. 28, Phys 112, 6:30-7:30.

·         History of SI https://en.wikipedia.org/wiki/International_System_of_Units

·         Effect of Measurement Error on SPC.pptx

·         appraiser-variation-in-gage-rr-measurement.pdf Good case study, a bit technical.

·         Gage R&R.pptx ANOVA version page 284 in text.

·         Measurement Uncertainty.docx Optional but deep reference.

·         SPC Montgomery ch08.ppt Slides 45-54 important for HW 8.34

 

 

Project reports due the Monday after Spring Break. You May turn in earlier if you like.

 

Week 9: Chapter 9, CUSUM, Exponentially Weighted Moving average charts and Arithmetic Moving Average charts.

·         Exercise 8_34 data.xls

·         Weighted moving average charts.pptx

·         SPC Montgomery ch09.ppt

·         exercise 9.14 data.xls

·         Basic Acceptance Sampling plans

 

 

Week 10: March 14-19 Spring Break

 

Week 11: March 21-25: (this is week 10 of classes)

          Group Project Presentations this week.

·         HW 7: Problem 8.34, due Wednesday March 22.

 

Week 12 March 27-March 31: (this is week 11 of classes) Acceptance sampling.

·         HW 8: Problem 9.14, due Wednesday April 5.

·         exercise 9.14 data.xls

·         Acceptance Sampling.pptx

·         SPC Montgomery ch15.ppt

·         basic acceptance sampling plans from older version of Montgomery

·         double sampling acceptance sampling plans

·         HW 9 due Wednesday, April 5. Tables from basic acceptance sampling plans

 

“Suppose that the AQL is agreed to be 2% defective per lot. Consider the OC curve for the sampling plan with N=200, n=20 and c=0.

a. What is the Producer’s Risk if the true proportion of defectives is 1%?

b. What is the Consumer’s Risk if the true proportion of defectives is 4%?

 

 

Week 13 April 3-7: (this is week 12 of classes).

·         Two-way Anova fixed effects-1.pptx

·         problem 5_10.xls example data from slides

·         SPC Montgomery ch13.ppt Examples 13.6, 13.7 and 13.8 very important.

 

 Week 14 April 10-14:  (this is week 13 of classes)

·         problem 13_3.xls HW10 Problem 13.3 due Wednesday April 12.

·         exercise 13_15.xls

·         SPC Montgomery Regression.ppt Theory behind modeling a process. Read up to and including slide 21.

·         SPC Montgomery RSM ch14.ppt

·         Improving Stable Processes Short Version.pptx

·         Section 14.2 in Montgomery text.

 

Week 15 April 17-21: (this is week 14 of classes)

·         Exam II, LILY G 126, Wednesday April 19, 6:30-7:30.

·         https://www.youtube.com/watch?v=XYrZINKyQMQ           3 minutes 9001

·         https://www.youtube.com/watch?v=Rg4ifmW5eiI               20 minutes good

·         https://www.youtube.com/watch?v=7pXu0qxtWPg          deming doing the bean box (minute 14 on good)

·         ISO 9000 overview.ppt

·         ISO History (brief) and basic facts.pptx More can be found on ISO web pages.

·         http://www.isbu-info.org/all_about_shipping_containers.html

·         http://en.wikipedia.org/wiki/Intermodal_container

·         Six Sigma material from the text “What Is Six Sigma”.

 

Week 16 (week 15 of classes)

·         https://www.iso.org/the-iso-story.html#0 concise review of ISO history

·         Real early six sigma

·         SPC_Six Sigma_Intro_CML.pptx

·         QMS, ISO and Six Sigma.pptx

·         Exam II.docx

 

 

Old Exams

             Recent SPC Exams

 Other Links:

             http://owl.english.purdue.edu/  Purdue Online Writing Lab.

             http://wordprocessing.about.com/od/microsoftword2007/a/researchpapers07.htm: Good reference on how to properly cite material.

             American Society for Quality Certifications and Handbook    

            For general information on the American Society for Quality go to

            http://www.asq.org/

            For a really good glossary of terminology go to

            http://www.asq.org/glossary/

            For information on the Baldrige National Quality Program go to

            http://www.baldrige.nist.gov/

 Handouts:

1. Basic Concepts:

·         Handout1 ; Quality Control: Then and Now.

·         Basic Tools; Pareto Charts, Flowcharts and Fishbone Diagrams.

·         Basics of Defining Processes.ppt

·         Measures.ppt

·         Displaying Measures.ppt

·         Diagnosing Variability.ppt

·         Basic terminology and Figures.docx

2. Failure Modes and Effects Analysis:

·         FMEA Material.ppt (courtesy of Chad Laux)

3. Control Chart Concepts for Measurement Data:

·         Basic Chart Concepts.pptx

·         Xbar and R charts.pdf (text)

·         Individual and XmR charts.pdf (text)

·         Moving Average Charts.pdf

·         Geometric Moving Average Charts.pdf

4. Effective use of Control Charts and Basic Tools:

·         Rational Subgrouping.pdf (text)

·         Rational subgrouping example

·         Subgrouping Example.pdf

·         Deming's 14 Points.pdf (text)

·         Deming's 14 Points Revisited.docx

5. Capability and Improving Stable Processes:

·         Basics of Capability.ppt

·         Improving Stable Processes.pdf

·         Taguchi and Response Surfaces.pdf

·         Taguchi and Response Surface Background.pdf

6. Measurement System Analysis:

·         Inadequate Measurement Units.pdf (text)

·         Basic and Derived units and the Pyramid of Standards

·         Measurement Analysis.pdf

·         appraiser-variation-in-gage-rr-measurement.pdf Reasonable background paper.

·         Measurement Uncertainty.docx: Lot’s of technical background.

7. Attribute Charts and Acceptance Sampling:

·         Attribute data I.pdf (text)

·         Attribute Data II.pdf (text)

·         Basic Acceptance Sampling Plans.doc

·         Double Sampling Acceptance Sampling Plans.doc

8. Quality Management Systems (QMS), ISO and Six Sigma:

·         QMS and ISO 9000 Overview.ppt

·         QMS,ISO and Six Sigma.docx

Other Reading:

    1. Understanding Variation-the Key to Managing Chaos, by Donald J. Wheeler. SPC Press, ISBN 0- 945320-35-3. If you are teaching an in-house course to people and they know zip, this is really good for a business setting. Short, concise, to the point.

2. Implementing Six Sigma, by Forrest W. Breyfogle III. John Wiley and Sons, ISBN 0-471-29659-7. An absolute must reference for the Six Sigma afficianado. Well written, very detailed (~700 pages) but well organized so special topics are easy to find. The first third, or so, is written to be very accessible to anyone who is literate in Quality thinking but wants to get a framework for Six Sigma thinking. The last two thirds are mainly technical statistical topics used in Six Sigma implementation and require a fairly good background in statistics, but also well written.

3. Lean Manufacturing-Tools, Techniques and How to Use Them, by William M. Feld. St. Lucie Press, ISBN 1-57444-297-X. Concise and to the point (lean, so to speak J). I never could figure out a good definition of “lean”, but to borrow a euphemism from a U.S. Supreme Court ruling “You can’t define it, but you know it when you see it.”.

4. What is Six Sigma, Pande, P. and Holpe, L.. McGraw Hill, IBSN: 0-07-141270-0. An excellent primer for someone with a basic knowledge of SPC. Many in Industry use it as a primer for new hires.