CH 36

CHAPTER 36
Quality Assurance, Testing, and

Inspection
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 36-1
Deming’s 14 Points
TABLE 36.1
1. Create constancy of purpose toward improvement of product and service.
2. Adopt the new philosophy.
3. Cease dependence on mass inspection to achieve quality.
4. End the practice of awarding business on the basis of price tag.
5. Improve constantly and forever the system of production and service, to
improve quality and productivity, and thus constantly decrease cost.
6. Institute training on the job.
7. Institute leadership (as opposed to supervision).
8. Drive out fear so that everyone can work effectively.
9. Break down barriers between departments.
10. Eliminate slogans, exhortations and targets for zero defects and new levels of
productivity
11. Eliminate quotas and management by numbers, numerical goals. Substitute
leadership.
12. Remove barriers that rob the hourly worker of pride of workmanship.
13. Institute a vigorous program of education and self-improvement.
14. Put everybody in the company to work to accomplish the transformation
Robust Design
Figure 36.1 A simple example of robust design. (a) Location of two mounting holes on a sheet-metal
bracket, where the deviation of the top surface of the bracket from being perfectly horizontal is ±α. (b)
New location holes, whereby the deviation of the top surface of the bracket from being perfectly
horizontal is reduced to± α/2.
Taguchi Loss Function
Figure 36.2 (a) Objective function
value distribution of color density
for television sets. (b) Taguchi loss
function, showing the average
replacement cost per unit to correct
quality problems. Source: After G.
Taguchi.
Frequency and Normal Distribution Curves
Figure 36.3 (a) A histogram of the number of shafts measured and their respective diameters. This type of
curve is called frequency distribution. (b) A Normal distribution curve indicating areas within each range of
standard deviation. Note: the greater the range, the higher the percentage of parts that fall within it.
Frequency Distribution Curve
Figure 36.4 Frequency distribution

curve, showing lower and upper
specification limits.
Statistical Quality Control
Figure 36.5 Control charts used in

statistical quality control. The process
shown is in statistical control because
all points fall within the lower and upper
control limits. In this illustration sample
size is five and the number of samples is
15.
Constants for Control Charts
TABLE 36.2
Sample size A2 D4 D3 d2
2 1.880 3.267 0 1.128
3 1.023 2.575 0 1.693
4 0.729 2.282 0 2.059
5 0.577 2.115 0 2.326
6 0.483 2.004 0 2.534
7 0.419 1.924 0.078 2.704
8 0.373 1.864 0.136 2.847
9 0.337 1.816 0.184 2.970
10 0.308 1.777 0.223 3.078
12 0.266 1.716 0.284 3.258
15 0.223 1.652 0.348 3.472
20 0.180 1.586 0.414 3.735
Figure 36.6 Control
charts. (a) Process
begins to become out
of control because of
such factors as tool
wear (drift). The tool
is changed and the
process is then in
statistical control. (b)
Process parameters are
not set properly; thus
all parts are around the
upper control limit
(shift in mean). (c)
Control Charts Process becomes out
of control because of
factors such as a
change in the
properties of the
incoming material
(shift in mean).
Digital Gages with Microprocessors
Figure 36.7 Schematic
illustration showing integration
of digital gages with
microprocessor for real-time
data acquisition and SPC/SPQ
capabilities. Note the examples
on the CRT displays, such as
frequency distribution (see Fig.
36.3) and control charts (see
Fig. 36.4). Source: Mitutoyo
Corp.
Data for Standard Deviation Calculation
TABLE 36.3
Sample number x1 x2 x3 x4 x5 x R
1 4.46 4.40 4.44 4.46 4.43 4.438 0.06
2 4.45 4.43 4.47 4.39 4.40 4.428 0.08
3 4.38 4.48 4.42 4.42 4.35 4.410 0.13
4 4.42 4.44 4.53 4.49 4.35 4.446 0.18
5 4.42 4.45 4.43 4.44 4.41 4.430 0.04
6 4.44 4.45 4.44 4.39 4.40 4.424 0.06
7 4.39 4.41 4.42 4.46 4.47 4.430 0.08
8 4.45 4.41 4.43 4.41 4.50 4.440 0.09
9 4.44 4.46 4.30 4.38 4.49 4.414 0.19
10 4.42 4.43 4.37 4.47 4.49 4.436 0.12
Acceptance Sampling
Figure 36.8 A typical operating-

characteristics curve used in
acceptance sampling. The higher the
percentage of defective parts, the lower
the probability of acceptance by the
consumer. There are several methods
of obtaining these curves.
Liquid-Penetrant and Magnetic-Particle
Inspection
Figure 36.9 Sequence of operations for liquid-penetrant inspection to detect the presence of cracks
and other flaws in a workpiece. Source: Metals Handbook, Desk Edition. Copyright ©1985, ASM
International, Metals Park, Ohio. Used with permission.
Figure 36.10 Schematic illustration of

magnetic-particle inspection of a part with a
defect in it. Cracks that are in a direction
parallel to the magnetic field, such as in A,
would not be detected, whereas the others
shown would. Cracks F, G, and H are the
easiest to detect. Source: Metals Handbook,
Desk Edition. Copyright ©1985, ASM
International, Metals Park, Ohio. Used with
permission.
Radiographic Inspection
Figure 36.11 Three methods of radiographic inspection: (a) conventional radiography, (b)
digital radiography, and (c) computed tomography. Source: Courtesy of Advanced
Materials and Processes, November 1990. ASM International
Eddy-Current Inspection
Figure 36.12 Changes in eddy-current

flow caused by a defect in a workpiece.
Source: Metals Handbook, Desk Edition.
Copyright ©1985, ASM International,
Metals Park, Ohio. Used with
permission.
Holography
Figure 36.13 Schematic illustration of the basic optical system used in holography
elements in radiography, for detecting flaws in workpieces. Source: Metals Handbook,
Desk Edition. Copyright ©1985, ASM International, Metals Park, Ohio. Used with
permission.

CH 36

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CH 36

Uploaded by

Copyright:

Available Formats

CHAPTER 36

Quality Assurance, Testing, and

Figure 36.4 Frequency distribution

Figure 36.5 Control charts used in

Figure 36.8 A typical operating-

Figure 36.10 Schematic illustration of

Figure 36.12 Changes in eddy-current

You might also like