Quality

Fifth Edition

Donna C. S. Summers
University of Dayton

Prentice Hall
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CONTENTS
I S E T T I N G T H E STAGE 1 6 Process Capability
1 Quality Basics 3
Why Quality? 4 / Ingredients for Success 5 /
The Evolution of Modern Quality 9 / The
Future of Quality 19 / Who Is the American
Society for Quality? 20 / Summary 20 /
Lessons Learned 2 1 / Chapter Problems 2 1 /
Case Study 23
2 Quality Advocates 24
Quality Advocates 25 / Summary 38 / Lessons
Learned 40 / Chapter Problems 40 / Case
Studies 42
3 Quality Improvement: Problem
Solving 46
Problem Solving 47 / Steps in Process
Improvement 47 / Plan 49 / D o 76 /
Study 80 / Act 81 / Summary 93 / Lessons
Learned 93 / Chapter Problems 93 / Case
Studies 100
II CONTROL CHARTS FOR
VARIABLES 105
4 Statistics 107
Statistics 108 / Use of Statistics in Quality
Assurance 108 / Populations versus Samples 109 /
Data Collection 110 / Measurements: Accuracy,
Precision, and Measurement Error 1 1 2 / Data
Analysis: Graphical 1 1 4 / Data Analysis:
Analytical 120 / Central Limit Theorem 129 /
Normal Frequency Distribution 131 / Confidence
Intervals 134 / Summary 136 / Lessons
Learned 136 / Formulas 136 / Chapter
Problems 136 / Case Studies 144
5 Variable Control Charts 150
Control Chart Functions 151 / Variation 152 /
Control Charts for Variables 153 / XandR
Charts 154 / Summary 187 / Lessons
Learned 187 / Formulas 189 / Chapter
Problems 189 / Case Studies 197
214
Individual Values Compared with Averages 215 /
Estimation of Population Sigma from Sample
Data 217 / Control Limits versus Specification
Limits 218 / The 6cr Spread versus Specification
Limits 218 / Calculating Process Capability
Indices 220 / Summary 229 / Lessons
Learned 229 / Formulas 230 / Chapter
Problems 230 / Case Studies 232
7 Other Variable Control Charts 239
Individual and Moving-Range Charts 240 /
Moving-Average and Moving-Range Charts 242 /
A Chart Plotting All Individual Values 245 /
Multi-Vari Analysis 247 / Median and Range
Charts 248 / Run Charts 251 / A Chart for
Variable Subgroup Size 254 / Precontrol
Charts 255 / Short-Run Charts 257 /
Summary 262 / Lessons Learned 262 /
Formulas 262 / Chapter Problems 264 /
Case Studies 270
III CONTROL CHARTS FOR
ATTRIBUTES 273
8 Probability 275
Probability Theorems 276 / Permutations
and Combinations 280 / Discrete Probability
Distributions 283 / Continuous Probability
Distribution 291 / Distribution Interrelationships
and Approximations 292 / Summary 293 /
Lessons Learned 293 / Formulas 294 / Chapter
Problems 295 / Case Studies 299
9 Quality Control Charts for
Attributes 302
Attributes 303 / Charts for Nonconforming
Units 303 / Charts for Counts of Non-
conformities 317 / Summary 328 / Lessons
Learned 330 / Formulas 330 / Chapter
Problems 331 / Case Studies 341
VII
VIM CONTENTS

IV EXPANDING THE SCOPE Baldrige National Quality Award 458 / Six

OF QUALITY 349 Sigma 459 / Summary 465 / Lessons
Learned 466 / Chapter Problems 466 / Case
Study 467
10 Reliability 351
Reliability 352 / Reliability Programs 352 / 15 Benchmarking and Auditing 471
Product Life Cycle Curve 353 / Measures of
Reliability 355 / Reliability Engineers 360 / Benchmarking 472 / Auditing 474 /
Summary 361 / Lessons Learned 361 / Summary 480 / Lessons Learned 480 /
Formulas 362 / Chapter Problems 362 / Chapter Problems 480 / Case Studies 482
Case Studies 366
Appendix 1 Normal Curve Areas
11 Advanced Topics in Quality 369 P(Z ^ Zo) 486
Quality Function Deployment 370 / Design of
Experiments 377 / Failure Modes and Effects Appendix 2 Factors for Computing
Analysis 391 / Summary 399 / Lessons Central Lines and 3<r, Control Limits
Learned 399 / Chapter Problems 399 / for X, s, and R Charts 488
Case Studies 401
Appendix 3 Values of
12 Quality Costs 405 t Distribution 489
What Are Quality Costs? 406 / Defining Quality
Costs 407 / Types of Quality Costs 409 / Appendix 4 Cumulative Binomial
Quality-Cost Measurement System 412 / Probability Distribution 491
Utilizing Quality Costs for Decision
Making 416 / Summary 418 / Lessons Appendix 5 The Poisson
Learned 418 / Chapter Problems 419 / Distribution 502
Case Studies 420
Appendix 6 About PQ Systems 506
13 Product Liability 428
The Evolution of Product Liability 429 / Appendix 7 CHARTrunner
Warranties 429 / Liability Loss Control Software 507
Programs 430 / Product Liability Suits 440 /
Future Considerations 440 / Summary 441 / Appendix 8 Websites for
Lessons Learned 441 / Chapter Problems 441 /
Quality 525
Case Studies 443
Glossary 527
14 Quality Systems: ISO 9000, Supplier
Certification Requirements, the Answers to Selected Problems 537
Malcolm Baldrige Award, and
Six Sigma 450 Bibliography 539
Quality Systems 451 / ISO 9000 451 / Supplier
Certification Requirements 453 / ISO 14000: Index 547
Environmental Management 456 / Malcolm