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QUALITY
CONTROL
Chapter Thirteen
McGraw-Hill/Irwin Copyright © 2014 by The McGraw-Hill Companies, Inc. All rights reserved.
Learning Objectives
LO13–01: Illustrate process variation and explain
how to measure it.
LO13–02: Analyze process quality using statistics.
LO13–03: Analyze the quality of batches of items
using statistics.
13-2
Statistical Quality Control (SQC)
The
quantitative Assignable variation
aspects of • Variation that is caused by factors
that can be identified and managed
quality
management
Processes
usually exhibit Common variation
some variation • Variation that is inherent in the
process itself
in their output
13-3
Measuring Variation
13-4
Variation and Specifications
Upper specification – the maximum acceptable
value for a characteristic
Lower specification – the minimum acceptable
value for a characteristic
Traditional View of Variability Costs Taguchi’s View of Variability Costs
13-5
Process Capability
The ability of a process to consistently produce a
good or deliver a service with a low probability of
generating a defect
Specification limits – range of variation that is
considered acceptable by the designer or customer
Process limits – range of variation that a process is
able to maintain with a high degree of certainty
13-6
Process Capability
13-7
Process Capability
13-8
Process Capability Index (Cpk)
Ratio of the range of values
produced divided by the range of
values allowed
Shows how well the parts being
produced fit into the range
specified by the design
specifications
Cpk larger than one indicates
process is capable
When the two numbers are not
close, indicates mean has shifted Excel: Process Cap
ability
13-9
Example 13.1
The quality assurance manager is assessing the capability
of a process that puts pressurized grease in an aerosol
can. The design specifications call for an average of 60
pounds per square inch (psi) of pressure in each can with
an upper specification limit of 65 psi and a lower
specification limit of 55 psi. A sample is taken from
production and it is found that the cans average 61 psi
with a standard deviation of 2 psi.
What is the capability of the process?
13-10
Example 13.1: Solution
13-11
Process Control Procedures
Concerned with monitoring quality while the
product or service is being produced
Statistical process control - testing a sample
13-12
Process Control Measurements –
p-Charts
13-13
Creating p-Charts
13-14
Process Control Measurements –
c-Charts
13-15
Variable Measurement Process Control Charts – X-
bar and R-Charts
Size of samples
Preferable to keep small (usually 4 or 5 units)
Number of samples
Once chart set up, each sample compared to chart
Use about 25 samples to set up chart
Frequency of samples
Trade-off between cost of sampling and benefit of adjusting the
system
Control limits
Generally use z = 3
13-16
X-bar and R-Charts
13-17
Process Control Charts – Interpretation
13-18
Acceptance Sampling
Performed on goods that already exist to determine
what percentage of the products conform to
specifications
Executed through a sampling plan
Results include accept, reject, or retest
13-19
Acceptance Sampling – Purposes
Determine quality level
Ensure quality is within predetermined
level
13-20
Acceptance Sampling
Disadvantages Advantages
13-21
Acceptance Sampling – Designing a Sampling Plan
13-22
Operating Characteristic Curve
13-23