STAT
513
Quality Control MWF 1:30-2:20, Potter 262, Fall
2009
Instructor:
Professor Tom Kuczek (kuczek@stat.purdue.edu)
Office: 152 HAAS, 765-494-6051
Office hours: T-Th 2-3 or by appointment
Questions: When sending questions by e-mail, please put “SPC Question” in the header so that I can easily see that it is from one of my Quality Control students. I try to handle these e-mails first. Please do the same if you wish to arrange a time for a phone conversation (this is primarily for off-campus students) or a meeting outside of the listed office hours. With so many students, it is impossible to have office hours convenient for everyone, but we can always find time to meet or to talk.
Web Address: http://www.stat.purdue.edu/~kuczek/stat513
Grader: Pu-Tai
Yang (ptyang@purdue.edu) . Office Grissom 292, office hours Friday 10-12 a.m.
Telephone 765-496-3679.
Texts: Understanding Statistical Process Control, Wheeler and Chambers. SPC Press, ISBN 0-945320-13-2.
What is Six Sigma? Authors: Pete Pande and Larry Holpp. McGraw-Hill, ISBN 0-07-138185-6. (It is about $8 if you order if from Amazon.com).
Grades:
Grades will be determined in the following fashion. There
will be two midterms and one final exam. Each midterm is worth 100 points, the
final exam is worth 150 points and homework will be worth 50 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 410 points. Most people will
likely get an A or a B, however I have given C’s and D’s.
Exams: Exams are based primarily on lecture material and designated reading material. They are all closed book, closed notes. I have created two hyperlinks to folders entitled “Older SPC Exams” and “Recent SPC Exams”. The latter are from the last academic year. While exam questions vary in difficulty, the answers are generally quite brief given the time constraints on the exams.
Homework: In SPC, it is necessary for everyone to become familiar with the mechanics of creating and interpreting control charts of various types, creating and interpreting flowcharts, fishbone diagrams, Pareto charts etc. While much of this is not particularly exciting, anyone who is to use SPC properly must go through this. In this regard, you must bow to the inevitable. You are free to use any software package you wish.
Note: while individual homeworks
will likely be graded out of 10 points, at the end of the semester they will be
normalized to a 50 point total!!!!!!!!!!!!
Turning
in Homework:
Off Campus Students: Off campus students may submit their Homework directly to the TA (never to me) by sending it in as an e-mail attachment such as a Word or PDF file, etc.
On Campus Students: On Campus Students can turn in their Homework
in class or directly to the TA (his procedures for this will be posted). Late HW is ˝ off without a reasonable excuse.
Students registered under IE 530. If you do not turn the HW in class turn it in to the TA.
Students registered under Stat 513. If you do not turn the HW in class turn it in to Joy Nyenhuis, her mailbox is in HAAS 164. (Her e-mail is jnyenhui@purdue.edu).
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, they can also be applied to ordering, accounting, record keeping and customer satisfaction, among others. Principles of Quality management are applicable to all types of organizations.
Course Topics
1. Basic concepts.
2. Summarizing Data.
3. Basic Tools (flowcharts, fishbone diagrams, Pareto charts).
4. Shewhart Control Charts.
5. Facts about Control Charts.
6. Effective use of Control Charts.
7. Capability.
8. Use of Control Charts for Continual Improvement.
9. Setting the Process Aim.
10. Taguchi Methodology.
11. Topics for Measurement Charts.
12. Control Charts for Attribute Data.
13. Effective use of Attribute Data.
14. Acceptance Sampling.
15. ISO 9000:2008
16. Six Sigma.
17. FMEA- Failure Modes Effects Analysis
Announcement
No class Monday, Labor Day, Sept. 7.
No office hours Tuesday Sept. 29
No office hours Tuesday, November 10.
Office hours Thursday, November 12
will be 11 to 12
Old Exams:
Other Links:
Les Actualites : Relevant (yes, really…) recent articles related to course material.
American Society for Quality Certifications and
Handbook
For general information on the American Society for Quality go to
For information and past issues of Business Week go to
For information on the Baldrige National Quality Program go to
Handouts:
Handout1 ;
Quality Control: Then and Now.
Basic Tools; Pareto Charts, Flowcharts and Fishbone
Diagrams.
Text example 5_6.pdf
Handout2;
Some Moving Average Chart notes.
Handout3; Issues in Rational Subgrouping, Cases 1 and 2.
Handout4; Comments on Six Sigma from Mikel Harry’s book.
Handout6 ;
Acceptance Sampling: Double Sampling.
Handout7 ;
Acceptance Sampling Basics: Notation, Definitions and Operating Characteristic
Curves.
Handout8 ;
Measurement: Basic and Derived Units, Pyramid of Standards, Basic Terminology.
Inadequate Measurement Units.pdf
Regularly vs. Periodically collected data.pdf
Geometric Moving Average
Charts.pdf
appraiser-variation-in-gage-rr-measurement.pdf
improved-gage-rr-measurement-studies.pdf
Handout10 ; 2003 Baldrige Criteria
Overview.
Taguchi Methods and Response
Surface Methodology
Handout11 ; Some Taguchi lecture notes
from previous semester.
Taguchi.pdf ; Very Good Background
Material on Taguchi (due to Brad Evans).
FMEA Material; Material from a Six Sigma Green Belt course by Chad Laux.
IE530/Stat513 updated Fall
Description
Assignments: Will be revised as we progress through the Fall semester. For reading assignments, read them at the very BEGINNING of the week.
Also when a handout reading is assigned, it is a really good idea to download a hardcopy of the Handout to make notes on. Also, some of the handouts have somewhat small print which may not be easy to read in streaming video.
Week 1: Read Chapter1 and Handout 1.
Week 2: Read Chapter 2 and do problems 2.3 and 2.4 due Friday, September 4 in class (for in class students). Chapter 2 material is very basic and we will not spend a lot of time on it. Read Chapter 12 and download a copy of the handout “Basic Tools” which includes Pareto Charts etc.
Week 3: Read the section “Defining Processes” in the Short Course Folder” in the Handouts Section as well as Chapter 3. Homework 2, due Friday, September 11 of Week 3, is to make a flowchart of how you studied for one of your most recent (and difficult) final exams. Use the flowchart symbols in you flowchart.
Homework 3 consists of both problems 3.1 and 3.4 due Monday, September 21 of Week 5.
Week 4: Read Chapter 4. Do problem 4.1 due Friday, September 25 of week 5.
Week 5: Read Chapter 5. Monday we will cover Deming’s 14 Points Handout. Wednesday we will cover Example 5.6 Handout (from the text). Do problem 5.2 due Wednesday, September 30 of week 6. Friday or Monday we will look over Handout3:Issues in Rational Subgrouping……
Week 6:Finish Rational Subgrouping and go over Rules for detecting out of control and the concept of “White Space”. This varies from the Text. Begin reading Basics of Capability powerpoint from the SPC Course slides folder.
No office hours Tuesday Sept. 29
Exam
I, Friday, October 2. In class for on campus students.
Week 7: Read Chapter 6. Friday you will see the film “Right First Time” again. For HW due Wednesday, October 14, list ten things from the film relevant to course material. Recall that the DVD is on reserve in Potter Library for those on campus.
Week 8: Problem 6.1, parts a-e, due Friday, October 16. (There may be a typo in the answer in the back.) Read Chapter 7.
Week 9: Problem 7.1 due Wednesday, October 21 (except part f). Problem 7.2, parts a,b,c, due Friday, October 23. Read Chapter 8, especially pages 195, 198 and 199. Read Chapter 9. Read the Handout “Taguchi Methods and Response Surface Methodology”.
Week 10: Do exercise 9.4 due Wednesday, October 28. Read Moving Averages Chart handout and Geometric Moving Averages Chart handout. Read Chapter 10.
Week 11: Problems 10.1, 10.4 and 10.6 due Friday, November 6.
Read Chapter 11. Read handouts 6 and 7.
Week 12: ISO 9000:2008 handout. Homework Problem due Friday November 13:
“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: Exam II, Friday November 20.
Everything since the last exam and new material. More emphasis on the newer material.
Weeks 13 and 14: Six Sigma material from the text “What Is Six Sigma”.
Week 15: Taguchi Methodology (read web handout).
Final
Exam: Final Exam, Wednesday, December 16, 3:15-5:30 Math 175. There are people
on campus with conflicts, so notify me as soon as possible to fix a different
time.
EXAMS: Dates to be announced. All exams are closed book, closed notes.
Only calculators without communication capabilities will be allowed. Any formulas needed will be provided.
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. Statistical Quality Control, by Douglas Montgomery. John Wiley & Sons, ISBN 0-471-51988-X. Lots and lots of statistical techniques. Makes a good reference book.