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
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:

Announcements: No office hours Thursday, Jan. 25.



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 50 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 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.



·         Week 1: Read Chapter1 and  Quality Control (Then and Now).pptx. Movie “Right First Time” will be shown in class. 

·         Basic tools

·         pareto and quality.docx

·         Basics of Defining Processes.ppt 

·         3-Measures.ppt .

·         Montgomery ch01.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

·          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.

·         PDCA Cycle.pptx

·         4-Displaying Measures.ppt

·         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

·         Common Cause Variation.pptx

· . How does injection molding work?

·         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, 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.

·         Common Cause Variation.pptx

·         Individuals Charts.pptx

·         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.

·         One-Way ANOVA 3.21.pptx

·         HW4: Exercise 4.35 problem4_35.xls

·         problem4_35.pdf

·         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 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

·         Exercise 6_8 data.xls

·         Exercise 6_9 data.xls

·         Basics of Capability.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.


·         Deming.docx Deming’s 14 points updated.

· Compare early efforts to now.

· 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.

· 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.

·         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


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.

·         metrology videos.docx

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

·         Measurement Analysis.pptx

·         Effect of Measurement Error on SPC.pptx

·         Basic and Derived Units and the Pyramid of Standards

·         Metrology again:


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

·         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.

·         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 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.

·         exercise 9.14 data.xls

·         HW 9 due Wednesday, April 4. Tables from basic acceptance sampling plans

·         Acceptance Sampling.pptx

·         SPC Montgomery ch15.ppt

·         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).

·         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 9-13:  (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 16-20: (this is week 14 of classes)

·         Exam II, Wednesday, April 18, 6:30-7:30 pm, ME 1061.

·           3 minutes 9001

·               20 minutes good

·          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.



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


Week 16 (week 15 of classes)

· 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:

     Purdue Online Writing Lab.

    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


            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.

·         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.