Textbook Acceptance Sampling in Quality Control Third Edition Edward G Schilling Ebook All Chapter PDF

Acceptance Sampling in Quality
Control Third Edition Edward G.

Schilling
Visit to download the full and correct content document:
https://textbookfull.com/product/acceptance-sampling-in-quality-control-third-edition-e
dward-g-schilling/
More products digital (pdf, epub, mobi) instant
download maybe you interests ...
Indoor air quality: the latest sampling and analytical

methods Third Edition Hess-Kosa
https://textbookfull.com/product/indoor-air-quality-the-latest-
sampling-and-analytical-methods-third-edition-hess-kosa/
Theory of Sampling and Sampling Practice, Third Edition

Francis R Pitard
https://textbookfull.com/product/theory-of-sampling-and-sampling-
practice-third-edition-francis-r-pitard/
An Introduction to Acceptance Sampling and SPC with R

First Edition John Lawson
https://textbookfull.com/product/an-introduction-to-acceptance-
sampling-and-spc-with-r-first-edition-john-lawson/
Quality assurance and quality control in the analytical

chemical laboratory : a practical approach Second
Edition Konieczka
https://textbookfull.com/product/quality-assurance-and-quality-
control-in-the-analytical-chemical-laboratory-a-practical-
approach-second-edition-konieczka/
Urban wildlife management Third Edition Clark Edward
Adams
https://textbookfull.com/product/urban-wildlife-management-third-
edition-clark-edward-adams/
A first course in quality engineering integrating

statistical and management methods of quality Third
Edition Krishnamoorthi
https://textbookfull.com/product/a-first-course-in-quality-
engineering-integrating-statistical-and-management-methods-of-
quality-third-edition-krishnamoorthi/
Mechatronics and Control of Electromechanical Systems

1st Edition Sergey Edward Lyshevski
https://textbookfull.com/product/mechatronics-and-control-of-
electromechanical-systems-1st-edition-sergey-edward-lyshevski/
Endoscopic ultrasonography Third Edition Frank G. Gress
https://textbookfull.com/product/endoscopic-ultrasonography-
third-edition-frank-g-gress/
Food Safety - Quality Control and Management 1st

Edition Mohammed Kuddus
https://textbookfull.com/product/food-safety-quality-control-and-
management-1st-edition-mohammed-kuddus/
Acceptance Sampling in
Quality Control
Third Edition
1.00
PR
1–α
0.50
Pa
β
CR
0 p
PQL IQ CQL
Statistics: Textbooks and Monographs
A Series Edited by
D.B. Owen
Volume 1: The Generalized Jackknife Statistic, H. L. Gray and W. R. Schucany

Volume 2: Multivariate Analysis, Anant M. Kshirsagar
Volume 3: Statistics and Society, Water T. Federer
Volume 4:
Multivariate Analysis: A Selected and Abstracted Bibliography, 1957–1972,
Kocherlakota Subrahmaniam and Kathleen Subrahmaniam (out of print)
Volume 5: D
esign of Experiments: A Realistic Approach, Virgil L. Anderson and
Robert A. McLean
Volume 6: Statistical and Mathematical Aspects of Pollution Problems, John W. Pratt
Volume 7: Introduction to Probability and Statistics (in two parts) Part I: Probability;
Part II: Statistics, Narayan C. Giri
Volume 8: Statistical Theory of the Analysis of Experimental Designs, J. Ogawa
Volume 9: Statistical Techniques in Simulation (in two parts), Jack P. C. Kleijnen
Volume 10: Data Quality Control and Editing, Joseph I. Naus (out of print)
Volume 11: Cost of Living Index Numbers: Practice, Precision, and Theory, Kali S. Banerjee
Volume 12: Weighing Designs: For Chemistry, Medicine, Economics, Operations Research,
Statistics, Kali S. Banerjee
Volume 13: The Search for Oil: Some Statistical Methods and Techniques, edited by D. B.
Owen
Volume 14:
Sample Size Choice: Charts for Experiments with Linear Models, Robert
E. Odeh and Martin Fox
Volume 15: Statistical Methods for Engineers and Scientists, Robert M. Bethea, Benjamin
S. Duran, and Thomas L. Boullion
Volume 16: Statistical Quality Control Methods, Irving W. Burr
Volume 17: On the History of Statistics and Probability, edited by D. B. Owen
Volume 18: Econometrics, Peter Schmidt
Volume 19: Sufficient Statistics: Selected Contributions, Vasant S. Huzurbazar (edited by
Anant M. Kshirsagar)
Volume 20: Handbook of Statistical Distributions, Jagdish K. Patel, C. H. Kapadia, and
D. B. Owen
Volume 21: Case Studies in Sample Design, A. C. Rosander
Volume 22:
Pocket Book of Statistical Tables, compiled by R. E. Odeh, D. B. Owen,
Z. W. Birnbaum, and L. Fisher
Volume 23: The Information in Contingency Tables, D. V. Gokhale and Solomon Kullback
Volume 24: Statistical Analysis of Reliability and Life-Testing Models: Theory and Methods,
Lee J. Bain
Volume 25: Elementary Statistical Quality Control, Irving W. Burr
Volume 26:
An Introduction to Probability and Statistics Using BASIC, Richard
A. Groeneveld
Volume 27: Basic Applied Statistics, B. I. Raktoe and J. J. Hubert
Volume 28: A Primer in Probability, Kathleen Subrahmaniam
Volume 29: Random Processes: A First Look, R. Syski
Volume 30: Regression Methods: A Tool for Data Analysis, Rudolf J. Freund and Paul
D. Minton
Volume 31: Randomization Tests, Eugene S. Edgington
Volume 32: Tables for Normal Tolerance Limits, Sampling Plans, and Screening, Robert
E. Odeh and D. B. Owen
Volume 33: Statistical Computing, William J. Kennedy, Jr. and James E. Gentle
Volume 34: Regression Analysis and Its Application: A Data-Oriented Approach, Richard
F. Gunst and Robert L. Mason
Volume 35: Scientific Strategies to Save Your Life, I. D. J. Bross
Volume 36: Statistics in the Pharmaceutical Industry, edited by C. Ralph Buncher and
Jia-Yeong Tsay
Volume 37: Sampling from a Finite Population, J. Hájek
Volume 38: Statistical Modeling Techniques, S. S. Shapiro
Volume 39: Statistical Theory and Inference in Research, T. A. Bancroft and C.-P. Han
Volume 40: Handbook of the Normal Distribution, Jagdish K. Patel and Campbell B. Read
Volume 41: Recent Advances in Regression Methods, Hrishkesh D. Vinod and Aman Ullah
Volume 42: Acceptance Sampling in Quality Control, Edward G. Schilling
Other Volumes in Preparation
Acceptance Sampling in
Quality Control
Third Edition
Edward G. Schilling and Dean V. Neubauer

CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2017 by Taylor & Francis Group, LLC

CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Printed on acid-free paper

Version Date: 20161028
International Standard Book Number-13: 978-1-4987-3357-1 (Hardback)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been
made to publish reliable data and information, but the author and publisher cannot assume responsibility for the
validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copy-
right holders of all material reproduced in this publication and apologize to copyright holders if permission to publish
in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know
so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or
utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including pho-
tocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission
from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://
www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA
01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users.
For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been
arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for
identification and explanation without intent to infringe.
Library of Congress Cataloging-in-Publication Data
Names: Schilling, Edward G., 1931- | Neubauer, Dean V.

Title: Acceptance sampling in quality control/Edward G. Schilling,
Dean V. Neubauer.
Description: Third edition. | Boca Raton: CRC Press, 2017. | Includes
bibliographical references and indexes.
Identifiers: LCCN 2016039621 | ISBN 9781498733571 (hardback)
Subjects: LCSH: Acceptance sampling. | Sampling (Statistics)
Classification: LCC TS156.4 .S34 2017 | DDC 658.5/62–dc23 LC record
available at https://lccn.loc.gov/2016039621
Visit the Taylor & Francis Web site at

http://www.taylorandfrancis.com
and the CRC Press Web site at

http://www.crcpress.com
This text is dedicated to the memory of
Dr. Edward G. Schilling
1931–2008
and
My Parents
Virgil A. Neubauer
1931–2004
and
Fanchon K. Neubauer
1936–2014
and
To our wives Jean and Kimberly

Contents
Preface to the Third Edition.........................................................................................................xix

Note from the Series Editor for the First Edition......................................................................xxi
Foreword to the First Edition................................................................................................... xxiii
Preface to the First Edition..........................................................................................................xxv
Acknowledgments from the First Edition............................................................................. xxvii
Preface to the Second Edition....................................................................................................xxix
Authors.........................................................................................................................................xxxi
List of Tables............................................................................................................................. xxxiii
1. Introduction..............................................................................................................................1
Acceptance Quality Control....................................................................................................1
Acceptance Control and Process Control..............................................................................4
Process Quality Control...........................................................................................................4
Background of Acceptance Quality Control.........................................................................7
Top 10 Reasons for Acceptance Sampling.............................................................................9
Problems...................................................................................................................................10
References................................................................................................................................10
2. Probability and the Operating Characteristic Curve......................................................13

Probability................................................................................................................................13
Classical Definition............................................................................................................13
Empirical Definition..........................................................................................................13
Subjective Definition..........................................................................................................14
Random Samples and Random Numbers...........................................................................14
Counting Possibilities.............................................................................................................15
Probability Calculus...............................................................................................................19
Operating Characteristic Curve............................................................................................23
Software Applications............................................................................................................27
Excel .....................................................................................................................................27
Minitab.................................................................................................................................29
Problems...................................................................................................................................32
References................................................................................................................................33
3. Probability Functions............................................................................................................35
Probability Distributions.......................................................................................................36
Measures of Distribution Functions.....................................................................................39
Hypergeometric Distribution................................................................................................41
Binomial Distribution.............................................................................................................43
Poisson Distribution...............................................................................................................45
f-Binomial Distribution..........................................................................................................49
Negative Binomial Distribution............................................................................................51
Exponential and Continuous Distributions........................................................................53
ix
x Contents
Weibull Distribution...............................................................................................................55
Normal Distribution...............................................................................................................57
Summary of Distributions.....................................................................................................60
Tables of Distributions...........................................................................................................60
Hypergeometric Tables.....................................................................................................60
Binomial Tables..................................................................................................................63
Poisson Tables.....................................................................................................................64
Negative Binomial Tables.................................................................................................64
Exponential and Weibull Tables.......................................................................................65
Normal Distribution Tables..............................................................................................65
Summary..................................................................................................................................65
Useful Approximations..........................................................................................................66
Tests of Fit................................................................................................................................69
Software Applications............................................................................................................72
Excel .....................................................................................................................................72
Minitab.................................................................................................................................74
Problems...................................................................................................................................79
References................................................................................................................................80
4. Concepts and Terminology..................................................................................................83

Average Run Length of Type B Plans...................................................................................86
Sample Size and Lot Size.......................................................................................................87
Effect of Inspection Error.......................................................................................................90
Rectification.............................................................................................................................92
Curtailment..............................................................................................................................94
Tolerance and Confidence Intervals.....................................................................................97
Levels and Risks......................................................................................................................99
Choosing Quality Levels......................................................................................................101
Classification of Defects.......................................................................................................102
Measures of Sampling Plans: Terminology.......................................................................102
Graphs of Measures..............................................................................................................104
Specifying a Plan...................................................................................................................107
Software Applications..........................................................................................................108
Minitab...............................................................................................................................108
Problems................................................................................................................................. 110
References.............................................................................................................................. 111
5. Single Sampling by Attributes......................................................................................... 113

Operation............................................................................................................................... 113
Selection................................................................................................................................. 113
Tables of Poisson Unity Values...................................................................................... 114
Binomial Nomograph...................................................................................................... 116
f-Binomial Nomograph................................................................................................... 116
Thorndyke Chart.............................................................................................................. 118
Hypergeometric Tables................................................................................................... 119
Measures................................................................................................................................121
Contents xi
Excel...................................................................................................................................123
Minitab...............................................................................................................................125
Statgraphics.......................................................................................................................127
Problems.................................................................................................................................130
References..............................................................................................................................131
6. Double and Multiple Sampling by Attributes..............................................................133

Operation...............................................................................................................................134
Double Sampling..............................................................................................................134
Multiple Sampling...........................................................................................................134
Selection.................................................................................................................................135
Measures................................................................................................................................141
Double Sampling..............................................................................................................141
Multiple Sampling...........................................................................................................143
Further Considerations........................................................................................................151
Excel...................................................................................................................................151
Minitab...............................................................................................................................154
Statgraphics.......................................................................................................................154
Problems.................................................................................................................................156
References..............................................................................................................................157
7. Sequential Sampling by Attributes.................................................................................159

Operation...............................................................................................................................159
Selection.................................................................................................................................161
Measures................................................................................................................................163
Sequential Sampling for Defects per Unit.........................................................................165
Excel...................................................................................................................................166
Problems.................................................................................................................................170
References..............................................................................................................................171
8. Variables Sampling for Process Parameter.....................................................................173

Single Sampling for Process Parameter.............................................................................173
Acceptance Control Charts..................................................................................................175
Sequential Plans for Process Parameter (σ Known).........................................................179
Sequential Plans for Process Parameter (σ Unknown)....................................................187
Cumulative Sum Charts.......................................................................................................190
Problems.................................................................................................................................193
References..............................................................................................................................194
9. Bulk Sampling......................................................................................................................195
Construction of the Sample.................................................................................................196
Estimation..............................................................................................................................198
Sampling Plans......................................................................................................................207
Simple Random Sampling of a Unique Lot (Components of Variance Unknown)....209
Sampling from Stream of Lots............................................................................................212
xii Contents
Estimation of Testing and Reduction Variances..........................................................212

Estimation of Segment and Increment Variances........................................................213
Application of Plan to Stream of Lots...........................................................................214
ISO 10725................................................................................................................................216
Problems.................................................................................................................................218
References..............................................................................................................................219
10. Sampling by Variables for Proportion Nonconforming..............................................221

Specification Limits..............................................................................................................222
Assumptions and Theory....................................................................................................223
Operation...............................................................................................................................225
X Method..........................................................................................................................225
k Method............................................................................................................................225
Double Specification Limits............................................................................................226
Selection.................................................................................................................................231
Tables.................................................................................................................................231
Formulas............................................................................................................................232
Jacobson Nomograph for Plan Selection......................................................................233
Measures................................................................................................................................234
Jacobson Nomograph for Operating Characteristics..................................................234
Calculation: σ Known......................................................................................................235
Calculation: σ Unknown.................................................................................................236
Double Specification Limits............................................................................................240
Measures of Performance...............................................................................................242
M Method...............................................................................................................................243
Plans Based on Sample Range............................................................................................248
Example.............................................................................................................................250
Double Sampling by Variables............................................................................................252
Tolerance Intervals and Variables Plans for Percent Nonconforming..........................255
Sequential Plans for Proportion Nonconforming............................................................259
Derivation of n, k Formulas............................................................................................260
Need for Normality.........................................................................................................262
Minitab...............................................................................................................................262
Statgraphics.......................................................................................................................269
Problems.................................................................................................................................273
References..............................................................................................................................274
11. Attributes Sampling Schemes...........................................................................................277

Sampling Schemes................................................................................................................277
Quick Switching Systems....................................................................................................277
Tightened–Normal–Tightened Plans.................................................................................279
MIL-STD-105E and Derivative Standards.........................................................................279
Operation...............................................................................................................................281
Selection.................................................................................................................................283
Measures................................................................................................................................286
Scheme Properties.................................................................................................................287
Implementation of MIL-STD-105E.....................................................................................289
Contents xiii
Matching Individual Sampling Plans to MIL-STD-105E System Performance...........294

MIL-STD-105 Derivatives....................................................................................................296
ANSI/ASQ Standard Z1.4..............................................................................................297
ASTM International Standard E2234.............................................................................297
ISO Standard 2859............................................................................................................297
Minitab...............................................................................................................................300
Snap Sampling Plans!......................................................................................................300
Statgraphics.......................................................................................................................301
Problems.................................................................................................................................306
References..............................................................................................................................307
12. Variables Sampling Schemes............................................................................................309

MIL-STD-414.........................................................................................................................309
Operation............................................................................................................................... 311
Selection.................................................................................................................................313
Measures................................................................................................................................316
Implementation of Form 2...................................................................................................317
Implementation of Form 1...................................................................................................319
Implementation of Plans for Range and Variability Known..........................................320
Match between MIL-STD-414 and MIL-STD-105E..........................................................320
Conversion of MIL-STD-414 to ANSI/ASQ Z1.9.............................................................321
MIL-STD-414 Derivatives....................................................................................................322
ANSI/ASQ Z1.9...............................................................................................................322
ISO 3951-1..........................................................................................................................323
Excel...................................................................................................................................326
Minitab...............................................................................................................................327
Statgraphics.......................................................................................................................327
Problems.................................................................................................................................334
References..............................................................................................................................335
13. Special Plans and Procedures............................................................................................337

No-Calc Plans........................................................................................................................337
Lot Plot Plans.........................................................................................................................339
Narrow-Limit Gauging........................................................................................................344
Mixed Variables: Attributes Plan........................................................................................354
Advantages and Disadvantages of Mixed Plans.........................................................356
Generalized Mixed Dependent Procedure...................................................................357
Measures: Independent Mixed Plan..............................................................................358
Measures: Dependent Mixed Plan.................................................................................360
MIL-STD-414 Dependent Mixed Plans.........................................................................365
Comparison of Independent and Dependent Mixed Plans.......................................366
Comparison of Mixed with Other Type Plans.............................................................367
Problems.................................................................................................................................368
References..............................................................................................................................369
xiv Contents
14. Series of Lots: Rectification Schemes...............................................................................371

Single-Sampling AOQL Plan...............................................................................................372
Dodge–Romig Sampling Scheme.......................................................................................373
Operation..........................................................................................................................374
Selection.............................................................................................................................374
Measures............................................................................................................................381
Further Considerations...................................................................................................381
Constructing LTPD Plan with Minimum ATI.........................................................386
Constructing AOQL Plan with Minimum ATI........................................................388
Anscombe Rectifying Inspection Procedure.....................................................................391
Operation..........................................................................................................................391
Selection.............................................................................................................................392
Measures............................................................................................................................394
Credit-Based Schemes..........................................................................................................395
Dodge–Romig Plan Derivatives.........................................................................................398
Excel...................................................................................................................................398
Problems.................................................................................................................................407
References..............................................................................................................................407
15. Continuous Sampling Plans..............................................................................................409

Dodge Continuous Plans.....................................................................................................409
Dodge CSP-1.....................................................................................................................409
Dodge–Torrey CSP-2 and CSP-3....................................................................................412
Measures of CSP-1, 2, and 3............................................................................................415
Stopping Rules and Selection of CSP-1 Plans..............................................................420
Multilevel Plans....................................................................................................................423
Tightened Multilevel Plans..................................................................................................427
Block Continuous Plans.......................................................................................................428
Wald–Wolfowitz Plan......................................................................................................428
Girshick Plan.....................................................................................................................430
MIL-STD-1235B.....................................................................................................................431
MIL-STD-1235B Derivatives................................................................................................439
Excel...................................................................................................................................439
Problems.................................................................................................................................443
References..............................................................................................................................444
16. Cumulative Results Plans..................................................................................................445

Skip-Lot Sampling Plans......................................................................................................445
SkSP-1................................................................................................................................445
SkSP-2................................................................................................................................447
Chain Sampling Plans..........................................................................................................453
ChSP-1...............................................................................................................................453
Two-Stage Plans...............................................................................................................457
Contents xv
Deferred Sentencing Schemes.............................................................................................458

Demerit Rating Plan.............................................................................................................462
CRC Plan................................................................................................................................466
Excel...................................................................................................................................468
Problems.................................................................................................................................474
References..............................................................................................................................475
17. Compliance Sampling.........................................................................................................477

LSP..........................................................................................................................................478
Procedure..........................................................................................................................478
Protection..........................................................................................................................479
Producer’s Risk................................................................................................................481
Examples of LSP Applications.......................................................................................482
TNT Scheme...........................................................................................................................484
Procedure..........................................................................................................................485
Protection..........................................................................................................................485
Selection.............................................................................................................................487
Quick Switching System......................................................................................................489
MIL-STD-1916.......................................................................................................................494
Structure............................................................................................................................494
Operation..........................................................................................................................494
Implementation................................................................................................................496
Measures............................................................................................................................498
Simplified Grand Lot Procedure.........................................................................................499
Simon’s Approach............................................................................................................500
Simplified Procedure: Attributes...................................................................................502
Example: Attributes.........................................................................................................503
Simplified Procedure: Variables.....................................................................................504
Continuing Series of Lots................................................................................................510
Nomograph for Samples Having Zero Defectives...........................................................515
Accept on Zero Plans............................................................................................................515
U.S. Department of Defense Approach.........................................................................515
Squeglia Plans...................................................................................................................516
AoZ and AQL Plans.........................................................................................................517
Chain Sampling Alternative...........................................................................................519
The Zero Acceptance Number Chained Quick Switching System...........................521
Summary...........................................................................................................................524
Excel...................................................................................................................................525
LSP Plans......................................................................................................................525
TNT Plans.....................................................................................................................525
QSS Plans......................................................................................................................527
MIL-STD-1916 Plans...................................................................................................537
Chain Sampling Alternative Plans............................................................................538
Zero Acceptance Number Chained Quick Switching System Plans...................538
xvi Contents
Minitab...............................................................................................................................543
LSP Plans......................................................................................................................544
Squeglia Plans..............................................................................................................545
Statgraphics.......................................................................................................................545
MIL-STD-1916 Plans...................................................................................................545
Problems.................................................................................................................................547
References..............................................................................................................................548
18. Reliability Sampling...........................................................................................................551

Censored Sampling...............................................................................................................552
Variables Plans for Life Testing and Reliability (Juran 1999)..........................................554
Handbook H-108...................................................................................................................555
Operation..........................................................................................................................556
Failure Terminated......................................................................................................558
Time Terminated..........................................................................................................558
Sequential.....................................................................................................................558
Proportion Failing by Specified Time.......................................................................558
Selection........................................................................................................................558
Example of H-108 Application.......................................................................................561
Failure Terminated......................................................................................................561
Time Terminated..........................................................................................................561
Sequential.....................................................................................................................563
Proportion of Lot Failing by Specified Time...........................................................563
Measures.......................................................................................................................564
Technical Report TR7............................................................................................................565
Mean Life Criterion..........................................................................................................566
Hazard Rate Criterion.....................................................................................................568
Reliable Life Criterion.....................................................................................................568
TR7 Tables.........................................................................................................................568
Operation..........................................................................................................................569
TR7 with the MIL-STD-105E System.............................................................................576
Problems.................................................................................................................................578
References..............................................................................................................................579
19. Administration of Acceptance Sampling........................................................................581

Selection and Implementation of a Sampling Procedure................................................583
Determining Quality Levels................................................................................................586
Setting AQL.......................................................................................................................587
Setting AOQL....................................................................................................................590
Setting IQ...........................................................................................................................590
Setting LTPD (or LQ).......................................................................................................590
Relation of Levels.............................................................................................................591
Setting PQL and CQL......................................................................................................593
Contents xvii
Economic Considerations....................................................................................................593
Mandatory Standards...........................................................................................................595
Basic Principle of Administration.......................................................................................596
Problems.................................................................................................................................596
References..............................................................................................................................597
Answers to Problems..................................................................................................................599
Appendix......................................................................................................................................615
Index..............................................................................................................................................829
Preface to the Third Edition
As I prepared to work on this edition, I wondered what has changed since the last edition,
what topics may have been omitted from that edition due to time, and which topics would be
of most interest to readers. I spent several years converting many of the old military accep-
tance sampling standards to American Society for Testing and Materials (ASTM) standards,
which means that they are now regularly reviewed and supported. Companies that have
traditionally used military standards can now refer to these new ASTM standards as they
contain the same tables. The reader will find out more about these ASTM s tandards in the
chapters covering these types of sampling plans.
As for omitted topics, I considered the addition of multivariate sampling and sampling
plans based on Cpk. In the end, I decided that readers would be particularly interested in
two topics—the implementation of computer spreadsheets and software in the design and
the evaluation of sampling plans and additional material on compliance sampling plans.
The last time I saw Ed Schilling, we met in my RIT office and he expressed his interest
in having me include a CD with the 3rd edition of this book that would include the Excel
templates I had developed for my acceptance sampling students at Rochester Institute of
Technology. Fortunately, since there is now a new book website put up by CRC Press at
www.crcpress.com/product/isbn/9781498733571, there is no need to include a CD with
the book that cannot be periodically updated. On the book website, the reader will find
not only a variety of Excel spreadsheets but also other files that are discussed at the end of
the appropriate chapters in this book. Ed believed, as I do, that readers are more likely to
understand and utilize the methods covered in this book when provided with a computer
approach. When I taught acceptance sampling, I provided my students with a number of
Excel spreadsheets for several types of plans. I believed that it was more likely that the stu-
dent could “hit the ground running” so to speak when they had to implement such plans
back on the job. This proved to be the case.
For this edition, I created several more Excel* templates to address sampling plans that
I didn’t use in my teaching, and which even existing commercial software does not handle.
At the end of many of the chapters in this text, I have included a section called “Software
Applications.” In this section, I discuss any Excel templates that I have available for the
reader on the book website as well as whether any commercial software will handle such
problems.
I got some help. I approached a few software companies for assistance in doing this
edition. Minitab,† Snap Sampling Plans!,‡ and Statgraphics§ have all been very generous in
providing me with either materials relating to how their program can design and analyze
acceptance sampling plans or a complimentary license for their product so I can showcase
* Excel is a registered trademark of Microsoft Inc. You must purchase Microsoft Office to install Excel as no free
demos are available.
† Minitab is a registered trademark of Minitab, Inc. A 30-day free demo of the software is available at
www.minitab.com.
‡ Snap Sampling Plans! is a registered trademark of Quality Assurance Solutions. The software home page can be
found at http://www.quality-assurance-solutions.com/Snap-Sampling-Plans.html. No demo is available.

§ Statgraphics is a registered trademark of Statpoint Technologies, Inc. A 30-day free demo of the software is
available at http://www.statgraphics.com/download_trial.
xix
xx Preface to the Third Edition
its features for acceptance sampling. At Minitab, I specifically thank Lou Johnson and his
associates, especially Yanling Zuo with whom I worked with to develop the initial accep-
tance sampling procedures included in Version 15 and that still exist in later versions.
Minitab also supplied some training materials that I could adapt to the examples in this
book. I also thank Dr. Neil Polhemus, CTO and director of Development for Statgraphics,
for his willingness to work with me to incorporate their Statgraphics Centurion XVII prod-
uct into this book. Finally, I thank Robert Broughton of Quality Assurance Solutions who
was also very supportive of my efforts to include his program, Snap Sampling Plans!,
among the suite of programs illustrated in this book to demonstrate the capabilities of his
software. Minitab, Snap Sampling Plans!, and Statgraphics represent excellent examples of
commercial software that can handle most of the acceptance sampling situations covered
in this book. There are a number of other lesser-known acceptance sampling programs for
sale on the Internet and a simple Internet search can find many of them.
One topic that continues to be important in the field of acceptance sampling is that of
compliance plans. The most common forms of these plans are accept on zero (AoZ) sam-
pling plans popularized by Nick Squeglia and his book Zero Acceptance Number Sampling
Plans (now in its 5th edition). As in the 2nd edition, Chapter 17 discusses lot sampling
plans, tightened-normal-tightened (TNT) plans, quick switching system (QSS) plans, MIL-
STD-1916, the simplified grand lot procedure, AoZ plans, and a chain sampling alterna-
tive. I expanded the section on QSSs as there has been considerable activity in this area
over the past more than 20 years. Much of this work comes from universities in India and
New Zealand, and the reader will find many references for these authors in Chapter 17.
Furthermore, recent work in 2011 by Govindaraju combining the ideas of many of these
types of plans into a zero acceptance number chained QSS has been added to this chapter.
The reader will find that many of the plans discussed in this chapter are supported by
Excel templates, Minitab, Snap Sampling Plans!, and Statgraphics.
Once again I thank my editor David Grubbs at Taylor & Francis Group for his patience
and understanding as I put in more time than expected in preparing this new edition due
to some health issues. Finally, and certainly not the least, I thank my wife, Kimberly, for all
her support as I worked on this edition. Without her having my back, this edition would
not have been possible.
Dean V. Neubauer
Horseheads, New York
Note from the Series Editor for the First Edition
The use of acceptance sampling has grown tremendously since the Dodge and Romig
Sampling Inspection Tables were first widely distributed in 1944. Throughout this period,
many people have contributed methods and insight to the subject. One of these contribu-
tors is the author of this book, which might better be identified as a compendium of accep-
tance sampling methods. The American Society for Quality Control has recognized
Dr. Schilling’s contributions by awarding him the Brumbaugh Award four times, first in
1973 and again in 1978, 1979, and 1981. This award is given each year to the author of
that paper published in either the Journal of Quality Technology or Quality Progress that the
American Society for Quality Control committee judges has made the largest single contri-
bution to the development of industrial applications of quality control.
Dr. Schilling has been employed both as an educator and as an industrial statistician.
This broad experience qualifies him to write this treatise as few others are qualified. The
beginner will find much interest in this work, while the experienced person will also find
many interesting items because of its encyclopedic coverage.
I am very pleased with the completeness and clarity exhibited in this book, and it is with
great pleasure that I recommend it to others for their use.
D. B. Owen
Department of Statistics
Southern Methodist University
Dallas, Texas
xxi
Foreword to the First Edition
As the field of quality control enters the 1980s, it is having new responsibilities thrust upon
it. The public is demanding products free from defects and often making these demands in
costly court cases. Management is demanding that all departments contribute to technical
innovation and cost reduction while still continuing to justify its own costs. The quality
control specialist is caught like others in this squeeze between perfect performance and
minimum cost. He or she needs all the help that fellow professionals can give, and Edward
Schilling’s book is a worthy contribution. Written by one of the foremost professionals in
the field, it is comprehensive and lucid. It will take its place as a valuable reference source
in the quality control specialist’s library.
My own first contact with a draft of the book came when I was teaching a quality con-
trol course to industrial engineers. Over the semester, I found myself turning to this new
source for examples, for better explanations of standard concepts, and for the many charts,
graphs, and tables, which are often difficult to track down from reference. Acceptance sam-
pling is not the whole of statistical quality control, much less the whole of quality control.
But Dr. Schilling has stuck to his title and produced a text of second-level depth in this one
area, resisting the temptation to include the other parts of quality control to make a “self-
contained work.” The added depth in this approach makes the text a pleasure for a teacher
to own and will make it a pleasure for students to use. This is one book that any student
should take into the world where knowledge is applied to the solution of problems.
Colin G. Drury
Department of Industrial Engineering
SUNY at Buffalo
Buffalo, New York
xxiii
Preface to the First Edition
The methods of statistical acceptance sampling in business and industry are many and
varied. They range from simple to profound, from practical to infeasible and naive. This
book is intended to present some of the techniques of acceptance quality control that are
best known and most practical—in a style that provides sufficient detail for the novice,
while including enough theoretical background and reference material to satisfy the more
discriminating and knowledgeable reader. The demands of such a goal have made it neces-
sary to omit many worthwhile approaches; however, it is hoped the student of acceptance
sampling will find sufficient material herein to form a basis for further explorations of the
literature and methods of the field.
While the prime goal is the straightforward presentation of methods for practical appli-
cation in industry, sufficient theoretical material is included to allow the book to be used as
a college-level text for courses in acceptance sampling at a junior, senior, or graduate level.
Proofs of the material presented for classroom use will be found in the references cited. It is
assumed, however, that the reader has some familiarity with statistical quality control pro-
cedures at least at the level of Irving W. Burr’s Statistical Quality Control Methods (Marcel
Dekker, Inc., New York, 1976). Thus, an acceptance sampling course is a natural sequel to
a survey course at the level suggested.
The text begins with a fundamental discussion of the probability theory necessary for
an understanding of the procedures of acceptance sampling. Individual sampling plans
are then presented in increasing complexity for use in the inspection of single lots. There
follows a discussion of schemes that may be applied to the more common situation of a
stream of lots from a steady supplier. Finally, specific applications are treated in the areas
of compliance sampling and reliability. The last chapter is concerned with the administra-
tion of acceptance control and, as such, is intended as a guide to the user of what sampling
plan to use (and when). Readers having some familiarity with acceptance sampling may
wish to read the last chapter first to put into context the methods presented.
This book views acceptance quality control as an integral and necessary part of a total
quality control system. As such, it stands with statistical process quality control as a bul-
wark against poor-quality products, whose foundations are rooted deep in mathematics
but whose ramparts are held only by the integrity and competence of its champions in the
heat of confrontation.
It is fitting that this book on acceptance sampling should begin with the name of
Harold F. Dodge. His contributions have been chronicled and are represented in the Dodge
Memorial Issue of the Journal of Quality Technology (Vol. 9, No. 3, July 1977). Professor
Dodge, as a member of that small band of quality control pioneers at the Bell Telephone
Laboratories of the Western Electric Company, is considered by some to be the father of
acceptance sampling as a statistical science. Certainly, he nurtured it, lived with it, and fol-
lowed its development from infancy, through adolescence, and on into maturity. In no small
way he did the same for the author’s interest in the field, as his professor and his friend.
Edward G. Schilling
xxv
Acknowledgments from the First Edition
Books are not made—they grow. It is impossible to acknowledge all the help and support
that has come from friends and associates in the development and construction of the pres-
ent volume. A few may be singled out not only for their individual contributions but also
as a sample of those yet unnamed. In particular, I thank Carl Mentch for suggesting the
possibility of such an undertaking in September of 1965 and for his unflagging encourage-
ment and help since that time. My thanks also go to Lucille I. Johnson whose technical and
editorial assistance helped to bring concept into reality. I also mention Dr. Lloyd S. Nelson
for his continued interest and suggestions and Dan J. Sommers and Professor Emil Jebe
for their constructive comments and theoretical insights. Certainly, my appreciation goes
to Dr. Donald P. Petarra, Dr. James R. Donnalley, and Dr. Pieter J. von Herrmann of the
General Electric Lighting Research and Technical Services Operation for their encourage-
ment and support throughout.
I am indebted to the American Society for Quality Control, the American Society
for Testing and Materials, the American Statistical Association, the Institute of
Mathematical Statistics, the Philips Research Laboratories, the Royal Statistical Society,
and Bell Laboratories for the permission to reprint a variety of materials taken from
their publications. I am also indebted to Addison-Wesley Publishing, Inc., for the per-
mission to reprint material from D. B. Owen, Handbook of Statistical Tables; to Cambridge
University Press for the permission to reprint material from E. S. Pearson, Tables of the
Incomplete Beta-Function; to McGraw-Hill Book Company for the permission to reprint
material from A. H. Bowker and H. P. Goode, Sampling Inspection by Variables, I. W. Burr,
Engineering Statistics and Quality Control, and J. M. Juran, Quality Control Handbook; to
John Wiley and Sons, Inc., and Bell Laboratories for the permission to reprint mate-
rial from H. F. Dodge and H. G. Romig, Sampling Inspection Tables; to Prentice Hall,
Inc., for the permission to reprint material from A. H. Bowker and G. J. Lieberman,
Engineering Statistics; to Stanford University Press for the permission to reprint material
from G. J. Lieberman and D. B. Owen, Tables of the Hypergeometric Probability Distribution,
and G. J. Resnikoff and G. J. Lieberman, Tables of the Non-Central t-Distribution; to the
European American Music Distributors Corporation for the permission to use the
English translation of “O Fortuna” from Carl Orff’s scenic cantata Carmina Burana; and
to my associates K. S. Stephens, H. A. Lasater, L. D. Romboski, R. L. Perry, and J. R.
Troxel for the material from their PhD dissertations taken at Rutgers University under
Professor Harold F. Dodge in a unique intellectual environment that was created and
sustained at the Statistics Center under the inspired direction of Dr. Ellis R. Ott and with
the dedicated administrative support of Dr. Mason E. Wescott.
Finally, these debts of gratitude are in terms of time and talent, how much more the debt
to my wife, Jean, and to my daughters, Elizabeth and Kathryn, who are as much a part of
this book as the author himself.
xxvii
Another random document with
no related content on Scribd:
battlement of rocks. Here a grassy sward smooth and level as a
billiard table was used as a croquet ground, this being at that time a
universal outdoor game in England. He had a democratic park. It had
no wall, and wire fences were as yet unknown, so he could not keep
deer. But on his fields we saw many cattle grazing. He told us he
was raising blooded stock, and expected the next year to commence
annual sales. We observed the very pleasant house beautifully
located in the valley, but he told us he was planning to remove it and
build a baronial hall in its place. I learned afterwards from Mr. Hoyle
that he had for some time kept two London architects employed on
designs for this hall, which designs he then employed another
draftsman to combine into a plan to suit himself, but had not as yet
determined on anything. As he was an old man, and had no one in
the world to leave this estate to, I could account for his devotion to it
only by his restless temperament, that must always find some new
outlet for his energy.
I, however, did not want him to expend any of this energy in
getting a steam-engine to suit him, and so the passing months
brought us no nearer to an agreement. My experience with
Ducommen et Cie. confirmed me in my decision not to let the
mechanical control of the engine in England pass out of my hands,
and Mr. Hoyle told me that he could not advise me to do so. Mr.
Whitworth was at that time in the death agonies of his artillery
system, and I did not meet him, but I learned through Mr. Hoyle that
he was highly indignant at me for presuming to take the position I
had done, and was immovably fixed in his own.
CHAPTER XIV
Study of the Action of Reciprocating Parts. Important Help from Mr. Frederick J.
Slade. Paper before Institution of Mechanical Engineers. Appreciation of Zerah
Colburn. The Steam Fire Engine in England.
fter the close of the Paris Exposition I devoted myself

in earnest to the study of the action of the
reciprocating parts of the engine, and will here give a
sketch of its development. In the high-speed steam-
engine the reciprocating parts were found to be a most
essential feature. Besides transmitting the pressure of
the steam to the crank they perform quite another office. It is their
inertia, relieving the crank from shocks on the dead centers, and
equalizing the distribution of the pressure on it through the stroke,
that makes the high-speed engine possible. I employed this inertia
before I knew anything about it. I had been occupied with the subject
of balancing. I had demonstrated practically that the centrifugal force
of a weight equal to that of the reciprocating parts, opposite the
crank and at the same distance from the center as the crank-pin,
perfectly balanced a horizontal engine, and had shown this fact
conclusively at this exposition.
The problem before me was, “What is it that makes my engine run
so smoothly?” I am not a mathematician, and so could not use his
methods. I got along by graphic methods and study of the motion of
the piston controlled by the crank. My recollection of the several
steps of my progress is quite indistinct. One thing I do remember
distinctly, and that is the help that I got from my friend Frederick J.
Slade, who was younger than I, but who died several years ago. Mr.
Slade was a mathematical genius. The firm of Cooper, Hewitt & Co.
were at a later date the pioneer makers in the United States of
wrought-iron beams and other structural shapes; and all their
designs and computations were the work of Mr. Slade. I had formed
his acquaintance in London in ’63. I met him again in Paris in ’67. He
was then in France in the employ of Abram S. Hewitt, investigating
the Siemens-Martin process of steel manufacture. He took much
interest in the engine. One day he brought to me a diagram
representing the two now famous triangles, and a demonstration of
them which he had made, showing that the ordinates, representing
the acceleration or retardation of the piston motion at every point, if
erected on the center line of the engine, terminate in a diagonal line,
which, with a connecting-rod of infinite length, would cross this
center line at its middle point.
This exhibited at once the equalizing action of the reciprocating
parts in a cut-off engine, absorbing the excessive force of the steam
at the commencement and imparting it to the crank at the end of the
stroke. I feel myself more indebted to Mr. Slade than to any one else,
and would here record the tribute of my grateful acknowledgment.
On January 30, 1868, I had the honor of reading a paper on the
Allen engine before the Institution of Mechanical Engineers. The
discussion of the paper was postponed until the next meeting, April
30, and the paper was ordered meantime to be printed and sent to
the members. The result was that on the latter date we had a very
interesting discussion. I may mention two things which occurred at
the first meeting, but do not appear in the report of the transactions.
When the secretary reached the statement that the acceleration of
the piston was greatest at the commencement of the stroke, the
president of the meeting, Sampson Lloyd, Esq., one of the vice-
presidents of the Institution, stopped the reading and said to me,
“You do not mean, Mr. Porter, that this is on the commencement of
the stroke, but at a point near its commencement.” I was obliged to
answer him that I intended to say that precisely on the dead center,
at the point where motion in one direction had ceased and that in the
opposite direction had not yet commenced, at that precise point the
stress on the crank was at its maximum, the crank having brought
the reciprocating parts to rest, and then by a continuance of the
same effort putting them in motion in the reverse direction.
Frederick J. Slade
After the reading was concluded, Mr. E. A. Cowper took the floor,
and stated that I was entirely mistaken in my explanation of this
action, that this had been investigated by a gentleman whose name
he gave but which I have forgotten, and who had demonstrated that
this retarding and accelerating action was represented by a curve,
which approximately he drew on the blackboard, but which he
excused himself from demonstrating there, as it would require the
use of the calculus and would take considerable time. For this
reason the discussion was postponed. At the next meeting Mr.
Cowper did not present this demonstration, and long afterwards he
wrote a letter to the editors of Engineering, stating that on full
investigation he had found the retardation and acceleration of the
piston to be represented by triangles and not by a curve. At the
discussion of the paper my view was supported by all the speakers
who addressed themselves to this point, except Mr. Cowper. An
especially careful and valuable exposition of the action of the
reciprocating parts was given Mr. Edwin Reynolds, then of the Don
Steel Works, Sheffield.
Zerah Colburn, the editor of Engineering, had always taken a
warm interest in my engine, and in the winter following the Paris
Exposition he invited me to furnish him the drawings and material for
its description in his paper. This I did, and from these he prepared a
series of articles written in his usual clear and trenchant style. These
will be found in Volume V of Engineering, the cuts following page 92,
and the articles on pages 119, 143, 158, 184, and 200.
Mr. Colburn’s articles in Engineering are so interesting in
themselves that I think I need make no apology for quoting from
them his remarks on this subject of the inertia of the reciprocating
parts, and those in which is depicted the revolutionary nature of the
high-speed engine, as viewed at that time.
After a prelude, with most of which the reader is already
acquainted, Mr. Colburn says:
“When a steam-engine is brought from abroad to the very spot
where the steam-engine originated, and where it has received, so far
at least as numbers are concerned, its greatest development, and is
claimed to be superior to those produced here, and to be able to run
advantageously at a speed hitherto deemed impracticable, its
promoters must not expect to have much attention paid to its claims
until such attention has been actually compelled, and then they must
be prepared for an ordeal of severest criticism....
“In employing a high grade of expansion, especially with the
considerable pressure of steam now usually carried in stationary
boilers, two serious practical difficulties are met with. The first arises
from the injurious effect of the sudden application of so great a force
on the centers, which the beam-engine, indeed, cannot be made to
endure, and the second is found in the extreme difference between
the pressures at the opposite ends of the stroke, which is such that
the crank, instead of being acted upon by a tolerably uniform force,
is rotated by a succession of violent punches, and these applied
when it is in its most unfavorable position....
“In the Allen engine the action of high speed causes all the
practical difficulties which lie in the way of the successful
employment of high grades of expansion combined with high
pressure of steam completely to disappear. The crank receives as
little pressure on the centers as we please; none at all if we like; the
force is applied to it as it advances, in a manner more gradual than
the advocates of graduated openings and late admission ever
dreamed of, and a fair approximation is made to a uniform rotative
force through the stroke. So that, in a properly constructed engine,
the higher the speed the smoother and more uniform and more silent
the running will be.”
After a page or more devoted to a demonstration of this action, Mr.
Colburn sums up the advantage of high speed in the following
illustration:
“Let us suppose that, in an engine making 75 revolutions per
minute, the reciprocating parts are of such a weight that the force
required at the commencement of the stroke to put them in motion is
equal to a pressure of 20 pounds on the square inch of piston. This
will not modify the diagram of pressure sufficiently to produce much
practical effect. But let the number of revolutions be increased to 150
per minute, the centrifugal force of these parts as the crank passes
the centers is now equal to 80 pounds on the square inch of piston,
and any pressure of steam below this amount acts only as a
relieving force, taking the strain of these parts partly off from the
crank. It makes no matter how suddenly it is admitted to the cylinder,
not an ounce can reach the crank; but as the latter advances, and
the acceleration of the reciprocating parts becomes less, the excess
of force not required to produce this becomes, in the most gradual
manner, effective on the crank.
“It will be observed how completely the designer has this action of
the reciprocating parts under control. He can proportion their speed
and weight to the pressure of steam in such a manner as to relieve
the crank from the blow on the center to whatever extent he may
wish. The notion that the reciprocating parts of high-speed engines
should be very light is therefore entirely wrong. They should be as
heavy as they can be made, and the heavier the better.
“The advantages of more rapid rotation are largely felt in the
transmission of power. Engineers understand very well that,
theoretically, the prime mover should overrun the resistance. Motion
should be not multiplied but reduced in transmission. This can
seldom be attained in practice, but high speed gives the great
advantage of an approximation to this theoretical excellence. On the
other hand, slow-speed engines work against every disadvantage.
Coupled engines and enormous fly-wheels have to be employed to
give a tolerably uniform motion; often great irregularities are
endured, or the abominable expedient is resorted to of placing the
fly-wheel on the second-motion shaft. Then comes the task of getting
up the speed, with the ponderous gearing and the enormous strains.
Slow motion also prevents the use of the belt, immeasurably the
preferable means of communicating power from a prime mover.
“But how about the wear and tear? The question comes from
friends and foes alike. The only difference is in the expression of
countenance, sympathetic or triumphant. The thought of high speed
brings before every eye visions of hot and torn bearings, cylinders
and pistons cut up, thumps and breakdowns, and engines shaking
themselves to pieces. It is really difficult to understand how so much
ignorance and prejudice on this subject can exist in this day of
general intelligence. The fact is, high speed is the great searcher
and revealer of everything that is bad in design and construction.
The injurious effect of all unbalanced action, of all overhanging
strains, of all weakness of parts, of all untruth in form or construction,
of all insufficiency of surface, increases as the square of the speed.
Put an engine to speed and its faults bristle all over. The shaking
drum cries, ‘Balance me, balance me!’ the writhing shaft and
quivering frame cry, ‘See how weak we are!’ the blazing bearing
screams, ‘Make me round!’ and the maker says, ‘Ah, sir, you see
high speed will never do!’
“Now, nothing is more certain than that we can make engines, and
that with all ease, in which there shall be no unbalanced action, no
overhanging strains, no weakness of parts, no untruth of form or
construction, no insufficiency of surface; in which, in short, there
shall be no defect to increase as the square of the speed, and then
we may employ whatever speed we like. ‘But that,’ interposes a
friend, ‘requires perfection, which you know is unattainable.’ No, we
reply, nothing unattainable, nothing even difficult, is required, but
only freedom from palpable defects, which, if we only confess their
existence, and are disposed to get rid of, may be easily avoided. It is
necessary to throw all conceit about our own work to the dogs, to lay
down the axiom that whatever goes wrong, it is not high speed, but
ourselves who are to blame, and to go to high speed as to our
schoolmaster.
“Among the many objections to high speed, we are often told that
the beam-engine will not bear it, and the beam-engine, sir, was
designed by Watt. In reverence for that great name, we yield to no
one. The beam-engine, in its adaptation to the conditions under
which it was designed to work—namely, a piston speed of 220 feet
per minute and a pressure of one or two atmospheres—was as
nearly perfect as any work of human skill ever was or will be; but we
wonder why the outraged ghost does not haunt the men who cling to
the material form they have inherited, when the conditions which it
was designed to meet have been all outgrown, who have used up
his factor of safety, and now stand among their trembling and
breaking structures, deprecating everything which these will not
endure.
“A journal and its bearings ought not only never to become warm,
but never even to wear, and, if properly made, never will do so with
ordinary care to any appreciable extent, no matter how great speed
is employed. It is well known that there exists a very wide difference
in bearings in this respect, some outlasting dozens of others. Now,
there need be no mystery about this: the conditions of perfect action
are so few and simple that it seems almost idle to state them. The
first is rigidity of a shaft or spindle between its bearings; but
everybody knows that if this is flexible, just in the degree in which it
springs, the journals must be cast in their bearings, though in actual
practice this perfect rigidity is not once in a thousand times even
approximated to. The point of excellence in the celebrated Sellers
bearing for shafting is that it turns universally to accommodate itself
to this flexure of the shaft, and the result is a durability almost
perfect.
“The second requirement, when we have a shaft capable of
maintaining perfect rigidity under all the strains it may be subjected
to, is abundant extent of bearing surface both in length and
circumference, a requirement, it will be seen, entirely consistent with
the first. It is a mistake to use journals of small diameter with the idea
that their enlargement will occasion loss of power on account of the
increased surface velocity, as, in fact, the coefficient of friction will
diminish in a greater ratio than that in which the velocity is increased.
In the Allen engine it is intended to make all shafts and journals too
large.
“But all is of little use unless the journal is round. High speed
under heavy pressure has a peculiar way of making it known when a
journal is not round, which, we suppose, is one of its faults. Now the
difference between a true cylindrical form and such an approximation
to it as a good lathe will produce in turning ordinarily homogeneous
metal is simply amazing; but when we compare with this the forms of
journals as commonly finished, the wonder is how many of them run
at all at any speed. When ground with a traversing wheel in dead
centers, which have themselves been ground to true cones, the only
known method by which a parallel cylindrical form can be produced,
their inequalities stand disclosed, and these are usually found to be
greater, often many times greater, than the thickness of the film of oil
that can be maintained in running. Then under pressure this film is
readily broken, the metal surfaces come into contact and abrasion
begins. But a true cylindrical journal swims in an oil-bath, separated
from its bearing at every point by a film of oil of uniform thickness,
and sustaining a uniform pressure, which cannot be anywhere
broken, and which has very little inclination to work out; and if it
revolves without deflection and the pressure per square inch of
surface is not sufficient to press out the lubricant, the speed is
absolutely immaterial and wear is impossible, except that due to the
attrition of the oil itself, which on hardened surfaces has no
appreciable effect.”
From the illustrations contained in these articles, I copy only the
following pair of diagrams with the accompanying note.
Pair of Diagrams from 18×30 Allen Engine at South Tyne Paper Mill, 108
Revolutions, Vacuum 28 Inches. Only Half Intended Load on Engine.
The winter of 1867-8 was devoted by me partly to watching the

dissolving view of my engineering prospects in England. It grew
more and more evident that through my difference with Mr.
Whitworth all my efforts and successes there would come to naught,
as they did.
But my friend, Mr. Lee, had even worse luck than I had. It will be
some relief from the monotony of my reverses if I go back a little and
tell of a reverse that befell another man. Curiously enough, Mr. Lee’s
reverse came from the overwhelming character of his success. The
English engineers had their breath quite taken away and lost their
heads, with the result that Mr. Lee lost his position. He was
ambitious to show his steam fire-engine doing its utmost. If he had
been wiser and had realized the limit of what his judges could stand,
he would have shown about one half its capacity and all parties
would have been happy.
To understand how naturally this most unexpected dénouement
came about, we must recall what the English people had been
accustomed to. In London fires were rare and trifling. Buildings were
low, built of brick with tile roofs. Open grates afforded the means of
cooking and of warming sufficiently for their climate. Every tenant of
a building who called in the fire department was fined five pounds,
which encouraged careful habits. The apparatus itself was
something quite ridiculous. It consisted of little hand-engines, worked
by about a dozen men. On the side of a corner building occasionally
one saw painted a distance in feet and inches. This meant that by
measuring this distance from this corner out into the street and
digging a little into the macadam pavement, a connection would be
found with the water-main. From this the water was permitted to flow
gently into an india-rubber saucer some 6 feet in diameter spread on
the ground. Out of this saucer the engine drew its water for a feeble
little stream.
Mr. Lee’s engine, with Worthington duplex pump, was, on its
completion, exhibited before a large company of invited guests,
principally officials of the fire department and prominent engineers.
The engine maintained a vertical column of water, delivered from a
much larger nozzle than had ever before been used in England, and
considerably over 100 feet high. There was also a corresponding
column of sparks from the chimney of the steam-pump. The
exhibition was made late in the afternoon of a short winter day, and
before it was over the coming darkness showed the column of
incandescent cinders to the best advantage. The few Americans
there enjoyed this miniature Vesuvius hugely. The Englishmen were
frightened out of their wits. Their unanimous verdict was that the
engine would evidently put out a fire, half a dozen of them for that
matter, but it would kindle twenty. And this where the engine had
been pushed to its utmost, and had not kindled one fire. Easton,
Amos & Sons instantly decided that they could never sell a steam
fire-engine under Mr. Lee’s management, and they discharged him
the next morning.
During the following season we had quite a steam-fire-engine
excitement. Some one, I have forgotten who, but think it was the
Duke of Sutherland, made a public offer of a thousand pounds
sterling for the best steam fire-engine, competition to be open to all
the world, the engines to be tested for six days in the park of the
Crystal Palace at Sydenham, in the month of July following. There
were a number of amusing incidents connected with that exhibition.
One was the following: The common council of New York City
determined that the city must have that prize, so they sent over
engine No. 7, a favorite engine, one of Mr. Lee’s make, and which
had been three or four years in service. A junket committee of the
city fathers accompanied it. The London Fire Department received
this delegation with great enthusiasm, and devoted itself to making
them happy. They took entire charge of their machine and exhibited
it in London to admiring crowds. A few days before the time fixed for
the opening of the trial they took the engine to Sydenham, where on
the way to its station it accidentally rolled down a hillside and was
pretty well broken up. Mr. Lee being in London was hurriedly sent for
to see if it could be repaired in time for the trial. He found that the
injuries were of so serious a nature that the repairs could not be
completed in less than three weeks. So that competitor was out of
the way. Their sympathizing friends were full of condolence, and
assumed all the cost of the repairs. They also proposed that when
the engine was put in proper order they should have an excursion
down the Thames to Greenwich and have there an exhibition of its
powers. So a steamboat was chartered and a large party
accompanied the machine to Greenwich. On arrival there it was
found that the two nozzles, a large one and a smaller one for long-
distance streams, which had been taken especial charge of by the
members of a fire company, had been accidentally dropped into the
Thames. The New York delegation were glad to get their engine
back to New York without further accident.
Easton, Amos & Sons also concluded that they would like that
prize. After they had taken the engine into their own hands, they
found a number of features which seemed to them to need
amendment, so they made some quite important changes. On the
second day of the trial this engine broke down and had to be
withdrawn.
I have forgotten how many competitors remained in the field, but
the prize was awarded to a London firm, builders of hand fire-
engines, who had only lately taken up this new branch of
manufacture. This successful firm applied to the government for an
order to supply steam fire-engines for the protection of the public
buildings. This application was referred to Easton, Amos & Sons, the
consulting engineers of the government. This firm concluded if
possible to have this order given to themselves, and applied to Mr.
Lee to recommend the changes in his engine necessary to put it in
proper working order. Mr. Lee replied that it was only necessary to
put the engine back in the precise condition in which he left it. They
finally agreed to do this, and employed Mr. Lee to direct the work.
When completed the engine was tried in the gardens of Buckingham
Palace, in competition with the prize winner, before a large body of
government officials. The Easton, Amos & Sons engine proved its
superiority on every point so completely that the government
immediately purchased it.
Some time before this, however, Mr. Lee had associated himself
with a capitalist for the manufacture of steam fire-engines in
England, and was then engaged on plans for them. His financial
associate was Judge Winter, by which title only he was known to us.
He was an American, and before the war was the proprietor of the
Winter Iron Works in Georgia (the precise location I have forgotten),
the most prominent engineering establishment in the Southern
States, in which business he had become wealthy. He will be
remembered by some gray heads as having been an exhibitor in the
New York Crystal Palace in 1853. He sent to it a steam-engine
bearing the name of “The Southern Belle.” This stood in the
machinery department, close to a Corliss engine, the two being the
only engines of any size which were exhibited there. This engine
was beautifully finished, polished pretty much all over, but its working
features were of the most ordinary character. Mechanically it was
valueless.
Judge Winter was a determined opponent of secession, and on
the adoption of that ordinance by the State of Georgia, was
compelled to fly from the country. He then took up his residence in
London, to which he had transferred such portion of his wealth as he
was able to convert into money.
He took a deep interest in the new steam fire-engine, and spent
part of nearly every day in the office where Mr. Lee and Mr. Taylor,
an American engineer whom Mr. Lee had associated with himself,
were engaged on their plans.
The point of interest to myself in this story lies here. The old judge
had no sound mechanical education, but was very fertile minded. He
came almost every morning with a new idea that he wanted
embodied. It was always absurd. He generally protested vigorously
against being overruled. When he was furnishing all the money he
could not see why he should not be allowed to have something to
say about it. I happened to be present in their office one morning
when he got particularly excited over their opposition. He was a stout
party, and on this occasion I had the fun of joining in the shout of
laughter that greeted him, when, after pacing the floor in silence for a
few minutes, he exclaimed, with his hand on the fabled seat of his
sympathies, “I thank my God that if there is one thing I am free from,
it is pride of opinion.”
My recollection of the above action of Easton, Amos & Sons and
of Judge Winter contributed materially to form my imagination of the
predicament in which I would certainly find myself, should I yield to
Mr. Whitworth the power to make whatever changes might occur to
him in my engine.
CHAPTER XV
Preparations for Returning to America. Bright Prospects.
aving but little practical work to occupy me that

winter, I devoted myself to getting out for Elliott Bros. a
second edition of my instruction book to accompany
the Richards indicator, and my paper for the Institution
of Mechanical Engineers and the illustrations and
material for Mr. Colburn’s articles on the Allen engine
published in Engineering.
I found in the library of the Manchester Philosophical Society a
copy of the twentieth volume of the “Memoirs of the French Academy
of Sciences,” containing the report of the experiments of M. Regnault
to determine the properties of steam, with the leaves uncut, of which
I was then able to make some use. I was anxious to obtain a copy of
this volume for myself, and also of Volume 21, containing other
memoirs by M. Regnault. This object I succeeded in accomplishing
when in Paris that winter through the kind interest of M. Tresca, the
well-known Sous-Directeur of the Ecole des Arts et Métiers. This
was a matter of so much difficulty, that a letter from M. Tresca to the
publisher was found not to be sufficient. It was necessary that M.
Tresca should personally identify me as the “savant” to whom he had
given the letter. I was then able to obtain both the volumes, which I
brought home with me on my return to America.
Now was the winter of my discontent made glorious summer, and
all the clouds that lowered about my enterprise in the deep bosom of
the ocean buried, by the receipt of a letter from Mr. Hope, telling me
that Mr. Allen’s report after his visit of inspection was of so entirely
satisfactory a character that, after full consideration, it had been
concluded to write me to leave everything in England in whatever
condition I might be obliged to, and return home and join with Mr.
Allen in the manufacture of the engines, for which ample capital
would be furnished. So in my ecstasy I went about quoting to myself
Shakespeare’s lines and applying them to my reviving fortunes. Mr.
Hoyle congratulated me warmly on this favorable turn in my affairs,
seeing clearly that I would never do anything with Mr. Whitworth,
unless on his own inadmissible terms.
After I had sobered down from my excitement, I began to consider
the matter carefully, and to determine upon the preparations that
ought to be made as a foundation for what, by judicious
management, should grow to be a great and profitable business. I
fully realized the responsibility that was devolved upon me, and
determined that both in foresight and prudence I would prove myself
equal to its requirements.
I wrote a glad acceptance of the proposition and expatiated on the
advantage we should enjoy from what I had learned in England. I
told them that the selection of a suitable location was of the first
importance, and suggested that a plot of twenty or thirty acres
should be purchased in the environs of a large manufacturing town,
affording a good labor market and having good railway facilities, and
where the land could be got at farm prices. I would plan shops on a
scale large enough for a great business and of a form adapted for
enlargement from time to time, and build at first a small part, which
as the business grew could be added to without alteration. I asked
them to look about for the best place, but do nothing further until I
got home, when I would have carefully studied plans, embodying the
most recent improvements in building and tools to lay before them.
I then entered with enthusiasm into the preparation of my plans.
The model shop, now in common use, had then lately been designed
by the firm of Smith & Coventry, tool makers of Salford, which is a
suburb of Manchester, separated from it only by a narrow stream,
the river Irwell, and their plan had been at once followed by the firm
of Craven Brothers of Manchester, also tool makers. It was, of
course, still unknown in the United States.
The general idea of this shop was taken from the nave and side
aisles of Gothic cathedrals. The central and wider portion, which we
may call the nave, was one story in height and was commanded by
the travelers, and its floor was occupied by the largest tools only, and
for erection. The side aisles were two stories in height. The smallest
work, of course, was on the upper story, and tools and work of
medium size on the floors below, the latter being transported by
carriages suspended from the floor above. No rails were laid or
gangways kept open on any floor. All transportation of heavy objects
was through the air. The great value of this improvement, made by
this firm in shop design, and which has brought this design into
general use, lay in its natural classification of the work. Travelers
were already quite common in England, but under them large and
small tools, often very small ones, were found mingled quite
promiscuously. Their shop had an entire glass roof, made on the
ridge and furrow plan, first used in the Crystal Palace in Hyde Park
for the International Exhibition of 1851. That roof would not answer,
however, in this climate, on account of our snow in winter, so I had to
plan a different one. But in every other respect their plan was
perfect. The columns, of course, at that time were of cast iron. These
were cast in pairs connected by a web, the longer columns in each
pair supporting the roof, the short ones the rails for the travelers.
In Smith & Coventry’s shop the traveler was operated from the
floor by means of a loop hanging from a wheel on the crab. The
arrangement was exceedingly convenient in every respect.
I obtained full detail drawings of Smith & Coventry’s shop. The
accompanying outline presents a cross-section of this shop, and is
figured to the dimensions I proposed to adopt. I proposed to build a
length of only 75 feet, which by successive additions could be
extended to 500 feet if required. Moreover, at first the office,
drawing-office, pattern shop, and storeroom, besides the machine
shop, in short everything, except only the engine and boiler, smith
shop and foundry, were to be accommodated in this one building. I
was greatly pleased with my plan, and felt sure that it would
commend itself to my associates, as no shop possessing these
conveniences then existed in the United States. I, however,
introduced one modification of the English shops, or rather one
addition. I had observed that reliance on the traveler for local work
involved a serious loss of time. I had seen in various shops men
standing idle, sometimes from fifteen to thirty minutes, waiting for the
traveler to be at liberty to come and give them a lift. It appeared
evident to me that the province of the traveler was to fetch and carry;
not to perform local work, unless of the heaviest class. So for the
latter purpose I provided swing cranes, which could be operated by
the workman himself without assistance. This also enabled one
traveler to cover a much longer extent of floor.
Cross-section of Machine Shop Proposed by Mr. Porter in 1868, after the Design
of Smith & Coventry.
Smith & Coventry had made numerous improvements on Mr.

Whitworth’s tools. I have already mentioned their arrangement which
made it possible to take up the wear of the lathe spindle bearings. In
the radial drill, an invention of Mr. Whitworth’s, as made by him, in
order to bring the drill to the right position longitudinally, the workman
was obliged to go to the end of the arm and turn the screw. From this
point he could not see his work, and had to guess at the proper
adjustment. I have seen him in the Whitworth works go back and
forth for this purpose three or four times, and have always doubted if
he got it exactly right after all. Smith & Coventry introduced an
elegant device by which the workman was able to make this
adjustment without moving from his place. They also first made the
arm of the radial drill adjustable vertically by power. By simply
reversing the curve of the brackets under Mr. Whitworth’s shaper
tables, they made these unyielding under the pressure of the cut.
This firm also first employed small cutting tools set in an arm which
was secured in the tool-post, and put an end to tool-dressing by the
blacksmith, which had caused a fearful waste of time, and also
encouraged idle habits among the workmen. This improvement has
since come into common use. Their system of grinding these small
tools interested me very much. The workman never left his machine.
He was provided with a number of tools, set in compartments in a
box. When a tool became dull he took it out, set it in the box upside
down, and substituted another. A boy went regularly through the
shop, took up all the upside-down tools, ground them, and brought
them back. The grindstones were provided with tool-holders and a
compound screw feed, by which the tools were always presented to
the stone at the same desired angle, and were prevented from
wearing out the stone by running into grooves or following soft spots.
The whole surface of the stone was used uniformly and kept in
perfect condition.
I picked up in that shop the solid wrench made with the elegant
improvement of inclining the handle at the angle of 15 degrees from
the line of the jaws; enabling it, by turning the wrench over, to be
worked within a radial angle of 30 degrees. This adapted it for use in
tight places. I brought the idea home with me and always supplied
my engines with wrenches made in that way. I offered the plan to
Billings & Spencer for nothing, but they did not think it worth making
the dies for. Mr. Williams was more appreciative. I believe it is now in
quite common use.
At that time toolmaking in this country, which has since become so
magnificently developed, was in many important respects in a
primitive condition, and I proposed to introduce into my shop every
best tool and method, adapted to my requirements, that I could find
in England. For this purpose I visited and carefully studied all the tool
works of good standing, and my final conclusion was that the best
tools for design, strength, solidity, facility of operation and truth of
work were those made by Smith & Coventry. This may be guessed
from the few examples I have given of their fertile mindedness and
advanced ideas. So I prepared a careful list of tools that I proposed
to order from them in time to be ready for use as soon as my shop
should be completed. I found also the remarkable fact that I could
obtain these tools, duty and freight paid, decidedly cheaper than
corresponding inferior tools could then be got from American
makers.
Before bidding good-by to England, I must tell the luck I had in
endeavoring to introduce Mr. Allen’s double-opening slide valve,
shown in the general view of my London exhibit, now in common use
the world over. No locomotive engineer would even look at it. Finally
I got an order from Mr. Thomas Aveling for one of these valves with
single eccentric valve-gear, to be tried on one of his road
locomotives or traction engines. Mr. Aveling is known to fame as the
inventor of the road locomotive and steam road roller. He once told
me how he came to make this invention. He was a maker of portable
engines in Rochester, which was the center of a wheat-growing
district. These engines were employed universally to drive threshing
machines. Horses were used to draw both the machine and the
engine from farm to farm. The idea occurred to him that this was
almost as foolish as was the practice of the Spanish muleteers, in
putting the goods they transported on one side of the animal and
employing a bag of stones on the other side to balance them. Why
not make the engine capable of moving itself and drawing the
threshing machine, and dispense with the horses altogether? So he
applied himself to the job and did it. Then it was found that the self-
propelling threshing-machine engines could draw a great many other
things besides threshing machines, and the business grew to large
proportions.
Mr. Aveling made an engine with valve and valve-gear from my
drawings, and I took a ride with him on it from Rochester to London,
the engine drawing two trucks loaded with the two halves of a fly-
wheel. The performance was entirely satisfactory. He said the engine
was handled more easily than any other he ever made, and it
maintained its speed in going up hill in a manner to astonish him,
which was accounted for by the double valve opening. The little
engine ran very rapidly, about 300 revolutions per minute, being
geared down to a slow motion of the machine, about 4 miles travel
per hour. With a single opening for admission it had admitted only a
partial pressure of the steam, but the double opening valve admitted
very nearly the whole pressure and made a sharp cut-off, all which I

Textbook Acceptance Sampling in Quality Control Third Edition Edward G Schilling Ebook All Chapter PDF

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

Textbook Acceptance Sampling in Quality Control Third Edition Edward G Schilling Ebook All Chapter PDF

Uploaded by

Copyright:

Available Formats

Acceptance Sampling in Quality

Control Third Edition Edward G.

Indoor air quality: the latest sampling and analytical

Theory of Sampling and Sampling Practice, Third Edition

An Introduction to Acceptance Sampling and SPC with R

Quality assurance and quality control in the analytical

A first course in quality engineering integrating

Mechatronics and Control of Electromechanical Systems

Endoscopic ultrasonography Third Edition Frank G. Gress

Food Safety - Quality Control and Management 1st

Volume 1: The Generalized Jackknife Statistic, H. L. Gray and W. R. Schucany

Edward G. Schilling and Dean V. Neubauer

© 2017 by Taylor & Francis Group, LLC

No claim to original U.S. Government works

Printed on acid-free paper

International Standard Book Number-13: 978-1-4987-3357-1 (Hardback)

Library of Congress Cataloging-in-Publication Data

Names: Schilling, Edward G., 1931- | Neubauer, Dean V.

Visit the Taylor & Francis Web site at

and the CRC Press Web site at

Dr. Edward G. Schilling

To our wives Jean and Kimberly

Preface to the Third Edition.........................................................................................................xix

2. Probability and the Operating Characteristic Curve......................................................13

4. Concepts and Terminology..................................................................................................83

5. Single Sampling by Attributes......................................................................................... 113

6. Double and Multiple Sampling by Attributes..............................................................133

7. Sequential Sampling by Attributes.................................................................................159

8. Variables Sampling for Process Parameter.....................................................................173

Estimation of Testing and Reduction Variances..........................................................212

10. Sampling by Variables for Proportion Nonconforming..............................................221

11. Attributes Sampling Schemes...........................................................................................277

Matching Individual Sampling Plans to MIL-STD-105E System Performance...........294

12. Variables Sampling Schemes............................................................................................309

13. Special Plans and Procedures............................................................................................337

14. Series of Lots: Rectification Schemes...............................................................................371

15. Continuous Sampling Plans..............................................................................................409

16. Cumulative Results Plans..................................................................................................445

Deferred Sentencing Schemes.............................................................................................458

17. Compliance Sampling.........................................................................................................477

18. Reliability Sampling...........................................................................................................551

19. Administration of Acceptance Sampling........................................................................581

found at http://www.quality-assurance-solutions.com/Snap-Sampling-Plans.html. No demo is available.

fter the close of the Paris Exposition I devoted myself

The winter of 1867-8 was devoted by me partly to watching the

Preparations for Returning to America. Bright Prospects.

aving but little practical work to occupy me that

Smith & Coventry had made numerous improvements on Mr.

You might also like