STAT
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.

**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:** 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.

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.

·
Basics of Defining Processes.ppt

·
3-Measures.ppt .

__Week 2__: No class Monday January 15, MLK holiday.
Read Chapter 3, a review of basics of Sampling and Probability Distributions.

·
Sampling and Quality
Control.pptx

·
SPC Basic sampling
distributions.pptx

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

· https://www.youtube.com/watch?v=HmCjr6cwDpI

·
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**.

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

·
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.**

·
SPC Montgomery slides ch06.ppt

·
Inadequate Measurement Units.pdf
When measurement unit is greater than sigma.

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

·
https://www.youtube.com/watch?v=tsF-8u-V4j4

·
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 C_{p} and C_{pk}, due **Wednesday
Feb. 14**.

·
Attribute Charts
and low defect rates.pptx

·
Effective use of
Attribute Charts.pptx

·
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**.

·
Data for 7_29.xls Data for 7_50.xls

·
Effect of Measurement
Error on SPC.pptx

·
Basic and Derived
Units and the Pyramid of Standards

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

__Week 8__: Chapter 8 on measurement analysis. **Regression material to be inserted .**

·
Monday,
review of exam topics.

·
SPC hw solutions 7_29 7_50.docx

·
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.

·
Weighted moving average charts.pptx

·
Basic Acceptance
Sampling plans

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

·
double sampling
acceptance sampling plans

**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.

·
Improving Stable
Processes Short Version.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 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.

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

·
**SPC_Six**** Sigma_Intro_CML.pptx**

·
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**

·
**SPC_Six**** Sigma_Intro_CML.pptx**

**Old
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

For a really good glossary of terminology go to

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

For information on the Baldrige National Quality Program go to

**Handouts**:

1. __Basic Concepts:__

·
Handout1 ;
Quality Control: Then and Now.

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

·
Basics
of Defining Processes.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__:

·
Xbar and R charts.pdf (text)

·
Individual
and XmR charts.pdf (text)

·
Geometric
Moving Average Charts.pdf

4. __Effective use of
Control Charts and Basic Tools__:

·
Rational
Subgrouping.pdf (text)

·
Rational
subgrouping example

·
Deming's
14 Points.pdf (text)

·
Deming's
14 Points Revisited.docx

5. __Capability and
Improving Stable Processes__:

·
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

·
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

**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.

**
**