INSPECTION

o Inspection and test typically include measurement of

an output and comparison to specified requirements
to determine conformity.
o Inspection performed for a wide variety of purposes:
CHAPTER 4 


Distinguishing between good and bad product
Determining if a process is changing
 Measuring process capability
 Rating product quality
 Securing product design information
INSPECTION AND SAMPLING PLAN  Rating inspectors’ accuracy

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 Determining the precision of measuring instruments 2

MAKING DECISIONS OF DETAILED INSPECTION PLANNING

INSPECTION

Product acceptance involves the disposition of a product based on

its quality. This disposition involves important decisions: Locate the
inspection
stations

 Conformance: Judging whether the product conforms to

specification
 Fitness for use: Deciding whether nonconforming products
are fit for use. • Checklist of
quality
characteristics
 Communication: Deciding what to communicate to insiders Select the
quality • Classify serious
characteristics
and outsiders. levels of defect
types

• The type of test: testing environment, testing

equipment, testing procedure, tolerances for
accuracy
• Sample size
Detailed
inspection • Sampling methods
planning • Type of measurement (attribute or variable)
• Conformance criteria (product tolerance limits)
3 • Processing methods for (non-)conforming 4
products
 INSPECTION ACCURACY
INSPECTION ACCURACY
Misinterpretation

The precision of an instrument is the

Inspectors’ extent to which the instrument repeats its
Inspection
measurement results when making repeated
accuracy
accuracy measurements on the same unit of
Precision
product. The deviation of measurement
error is denoted as σ(E). The lower σ(E) the
more precise instrument
Error of
measurement
An instrument’s bias is the extent to
which the mean value of a series of
Bias repeated measurements made by the
instrument differs from the true value.
The difference is often due to a
systematic error in the measurement
process.

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SAMPLING PLANS
INSPECTION ACCURACY

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 SAMPLING PLANS SAMPLING PLANS

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SAMPLING PLANS
Total costs (TC) of inspection alternatives:
SAMPLING PLANS
 No inspection: TC = N*p*A
 Sampling: TC = n*I + (N-n)*p*A*Pa + (N-n)*(1-Pa)*I Acceptable quality level (AQL) is the quality level desired by the
consumer. This is defined as the worst quality level that still
 100% inspection: TC = N*I
satisfies the customers.

Producer’s risk (α) is the probability that a shipment having exactly

Where: N = No. of items in lot; n = number of items in sample; this level of quality will be rejected
p = Proportion defective in lot; I = Inspection cost per item; A =
Damage cost incurred if a defective slips through inspection;  Rejecting a good (AQL) lot is a type I error
Pa = Acceptance probability of lot by the sampling plan  Consumers also desire low producer’s risk because sending
good materials back to the supplier disrupts the consumer’s
production processes
The break-even point: p(b) = I/A
 If p<p(b)  TC will be lowest with Sampling or No inspection
 If p>p(b)  TC will be lowest with 100% inspection

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 SAMPLING PLANS OPERATING CHARACTERISTIC CURVE

Rejectable quality level (RQL) (also known as Lot tolerance 1.0

Ideal OC curve
proportion defective - LTPD) defines unsatisfactory quality. α

Probability of acceptance
Consumer’s risk (β ) is the probability a shipment having exactly this level
of quality (the RQL) will be accepted
 Accepting a bad (RQL) lot is a type II error
 A common value for the consumer’s risk is 0.10, or 10 percent Typical OC curve

Indifferent quality level (IQL) is between AQL and RQL. It is

normally defined as the quality level that has an acceptable
probability of 0.5. β
AQL RQL
Proportion defective
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SAMPLING PLANS SAMPLING PLANS

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 SAMPLING PLANS SAMPLING PLANS

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SINGLE-SAMPLING PLANS
 States the sample size, n, and the
DOUBLE-SAMPLING PLANS
acceptable/Rejectable number of defectives (Ac &
Re)
 The accept-reject decision is based on the results of
one sample taken at random from a large lot
 If the quality characteristic of the sample passes the test
(defects k ≤ Ac), accept the lot
 If the sample fails (defects k >= Re) there may be
complete inspection of the lot or the entire lot is
rejected

 A good lot could be rejected if the sample includes an

unusually large number of defects
 A bad lot could be accepted if the quality in the sample is
better than in the lot
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 4.10 a) single sampling with general inspection level
AQL =ACCEPTABLE QUA LEVEL=1.5
N=1500=> level II
ATTRIBUTE SAMPLING => SAMPLE SIZE CODE K VARIABLE SAMPLING
=>n= 125
- Ac=5 -> K<= 5 : accept lot
- Re=6 -> K>=6 : reject lot
b) n= 125
- Ac=3 -> K<= 3 : accept lot
- Re=4 -> K>=4 : reject lot
c) n=50
- Ac=2 -> K<= 2 : accept lot
- Re=5 -> K>=5 : reject lot

4.16
a) single sampling plan for normal inspection b) incorrect because we dont inspect 100% of the lot 4.15 AQL=1% b) P(p%)=10% use table to find
AQL=4 21 N ~ 1200-1800 =>CODE K Ac=r=1 22

N=10000, level II c) P(p=4%)=? p=0,3% <AQL=> reduced ínspection => n.p=3,8%

sample size code is L Ac=r=14 a) sample size =64 ==> 1st n1=32 p=3,8/64=5,9%
n=200 n=200 p=4% => np=8 2nd n2=32
- Ac=14 -> K<= 14 : accept lot ==> P9p=4)=98,3% 1st sample AQL=1 Ac=0 c) n=32, p=4% => np=1,28 ~1,3
- Re=15 -> K>=15 : reject lot Re=4 Ac=r=0
2nd sample AQL=1 Ac=1 Rejection probability
Re=5 1-P(p=4%)=1-27,3%=72,7%
4.17 a) AQL=1
LEVEL II
N=900-1200
single-sampling plan use:
CODE J, n=80
a) Ac=2
Re=3
b) P(p=2)=50%
Ac=r=2
n=80, p=8
=> 26, p=3,25%