513/IE 530 - Spring 2018
Statistical Quality Control MWF
11:30-12:20 UNIV 003
12:30-1:20 UNIV 003
Instructor: Professor Tom Kuczek (kuczek AT purdue.edu)
Office: 152 HAAS, 765-494-6051
Office hours: 10:00-11:00 T-Th. Feel free to send questions by e-mail if more convenient.
Course Web Address: http://www.stat.purdue.edu/~kuczek/stat513
Announcements: There will be no class the week of April 23. Final grades will be posted at the beginning of finals week. If you have a question about your grade you may contact me after the grades are posted. Enjoy your summer!
TA: 11:30: Ryan Murphey (murph213 at purdue)
12:30: Chang Cheng (cheng338 at purdue)
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 60 points. There will be a group project worth 30 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.
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 60 point total for HW. Late HW is ½ off.
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. Seen students do it in Matlab too.
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: Regression and calibration to be added.
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.
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.
· Week 1: Read Chapter1 and Quality Control (Then and Now).pptx. Movie “Right First Time” will be shown in class.
· 3-Measures.ppt .
Week 2: No class Monday January 15, MLK holiday. Read Chapter 3, a review of basics of Sampling and Probability Distributions.
· https://www.youtube.com/watch?v=7pXu0qxtWPg Deming doing the bean box (minute 14 on good)
· 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.
· Montgomery slides montgomery ch03.ppt
· Homework 1, do problems 3.9 and 3.10, due Wednesday, January 24.
· https://www.youtube.com/watch?v=RMjtmsr3CqA . How does injection molding work?
· 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, Jan 31 of Week 4, is to make a flowchart of the main steps in the injection molding process (the one in the video) and include the main steps where you would collect data and which data to collect.
· Homework 3, problem 5.24, due Wednesday Jan 31.
· Rational subgrouping great example on Fixed Differences
· Rational subgrouping another example
· SPC Montgomery ch04-1.ppt Most of topics a review of hypothesis testing, pages 70-80 mandatory. The rest is a review.
· HW4: Exercise 4.35 problem4_35.xls
· SPC Montgomery ch05.ppt Introduces control charts, limits, rules and reviews basic tools.
Week 5: Read Chapter 6, Control Charts for Variables. Homework 5: Problem 6.8, parts (a) and (c), problem 6.9, parts (a) and (b). HW 4 due Wednesday, Feb. 7.
· Inadequate Measurement Units.pdf When measurement unit is greater than sigma.
· 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.
· https://www.youtube.com/watch?v=XbkMcvnNq3g Steve Jobs speaks about Juran.
· Stat 513/IE530 Group Project Guidelines.docx groups will be formalized this week. Reports due Friday before Spring Break. Presentations will begin the Wednesday 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 (a) and (c) and problem 6.9 part (a) and (c), for part (c) compute both Cp and Cpk, due Wednesday Feb. 14.
· SPC Exercise 5_24 solution.docx solution HW3
· Spc chapter 6 problems.docx solution to HW 4 5
Week 7: Finish Attributes charts and start Measurement System Analysis, Chapter 8.
· HW 6: Problems 7.29 part a) get control limits for various n, for b) get control chart, and 7.50, due Wednesday, February 21.
Week 8: Chapter 8 on measurement analysis. Regression material to be inserted .
· Monday, review of exam topics.
· No class Wednesday due to exam. I will have office hours during class time.
· Exam I, Wednesday Feb. 28 6:30-7:30 MATH 175.
· History of SI https://en.wikipedia.org/wiki/International_System_of_Units
· 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
· SPC Montgomery Regression.ppt Theory behind modeling a process. Read up to and including slide 21.
Project reports due by Friday before Spring Break. You May turn in earlier if you like.
Week 9: Chapter 9: Exponentially Weighted Moving average charts and Arithmetic Moving Average charts.
Week 10: March 12-17 Spring Break
Week 11: March 19-23: (this is week 10 of classes)
Group Project Presentations this week.
· HW 7: Problem 8.34, due Wednesday March 21.
Week 12 March 26-30: (this is week 11 of classes) Acceptance sampling.
· HW 8: Problem 9.14, due Wednesday April 4.
· HW 9 due Wednesday, April 4. Tables from basic acceptance sampling plans
· basic acceptance sampling plans from older version of Montgomery
HW 9: “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 2-6: (this is week 12 of classes).
· SPC Montgomery Regression.ppt Theory behind modeling a process. Read up to and including slide 21.
· 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 9-13: (this is week 13 of classes)
· problem 13_3.xls HW10 Problem 13.3 due Wednesday April 11.
· ISO History (brief) and basic facts.pptx More can be found on ISO web pages.
· Section 14.2 in Montgomery text.
Week 15 April 16-20: (this is week 14 of classes)
· Exam II, Wednesday, April 18, 6:30-7:30 pm, ME 1061.
· 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)
· 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
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.
For general information on the American Society for Quality go to
For a really good glossary of terminology go to
For information on the Baldrige National Quality Program go to
1. Basic Concepts:
· Handout1 ; Quality Control: Then and Now.
· Basic Tools; Pareto Charts, Flowcharts and Fishbone Diagrams.
2. Failure Modes and Effects Analysis:
· FMEA Material.ppt (courtesy of Chad Laux)
3. Control Chart Concepts for Measurement Data:
· Xbar and R charts.pdf (text)
· Individual and XmR charts.pdf (text)
4. Effective use of Control Charts and Basic Tools:
· Rational Subgrouping.pdf (text)
· Deming's 14 Points.pdf (text)
5. Capability and Improving Stable Processes:
6. Measurement System Analysis:
· Inadequate Measurement Units.pdf (text)
· 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)
8. Quality Management Systems (QMS), ISO and Six Sigma:
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.