School of Engineering and Technology, (SET)
 
AT72.05 : Quality Control and Management  3(3-0)
 
Course objectives:

The objective of this course is to impart knowledge on basic concepts of quality management as well as using statistical analysis in quality control and improvement. Advanced quality control techniques for six-sigma improvement process and various sampling techniques for quality inspection are also covered.
 
Learning Outcomes:
The students on the completion of this course would be able to
•         Identify basic requirements for application of quality management system
•         Implement total quality management and six-sigma programs
•         Construct control charts for quality variables and attributes
•         Analyse capability of manufacturing processes
•         Apply acceptance sampling procedures in lot-disposition decision making.
 
Pre-requisite(s):

None
 
Course Outline:
I.         Quality Concepts
1.    Approaches to Defining Quality
2.    Design and Manufactured Quality
3.    Economics of Quality

II.        Quality Management System
1.    Elements of Quality Systems
2.    Quality Assurance and Quality Cost Analysis
3.    ISO 9000 and Total Quality Management (TQM) Systems
4.    Quality Function Deployment
5.    Six Sigma

III.       Methods and Philosophies of Statistical Process Control
1.    Chance and Assignable Cause of Quality Variations
2.    Statistical Basics of the Control Chart
3.    Principles of Control Charts – Design, OC Curve and Average Run Length
4.    Pattern Analysis
5.    The Rest of the “Magnificent Seven”

IV.       Control Charts for Variables
1.    Average and Range Charts
2.    The S Chart and Variance Chart
3.    Control Chart with Various Sample Sizes
4.    Control Chart for Individual Measurements

V.        Control Charts for Attributes
1.    Control Chart for Fraction Nonconformings
2.    Control Charts for Nonconformities (Defects)
VI.       Process and Measurement System Capability Analysis
1.    Process Capability Ratios
2.    Process Capability Analysis
3.    Gage and Measurement System Capability Analysis

VII.     Other Types of Control Charts
1.    Cumulative Sum Control Chart
2.    Exponentially Weighted Moving Average Charts
3.    Other Charts - Short Production Runs, Acceptance, Group charts, etc.   

VIII.     Process Optimization with Designed Experiments
1.    Review on Design of Experiments
2.    Response Surface Methods
3.    Taguchi Methods

IX.       Acceptance Sampling for Attributes
1.    Single Sampling Plans
2.    Double, Multiple and Sequential Sampling Plans
3.    Military Standards: MIL STD 105E
4.    Dodge-Romig Sampling Plans

X.       Other Acceptance Sampling Techniques
1.    Acceptance Sampling for Variables
2.    Sampling Plan to Control the Process Fraction Defective
3.    Military Standards: MIL STD 414
4.    Sampling Plan to Give Assurance for Process Mean
 
 
Learning Resources:

Textbook:
D.C. Montgomery: Introduction to Statistical Quality Control, 7th edition, John Wiley & Sons, 2012.
 
Reference Books:
1.    J.R. Henderson: Six Sigma Quality Improvement with Minitab, 2nd edition, John Wiley & Sons, 2011.
2.    J. Banks: Principles of Quality Control, 1st edition, John Wiley & Sons, 1989.
3.    A.J. Duncan: Quality Control and Industrial Statistics, 5th edition, Irwin, 1986. 
4.    J.R. Evans, and W.M. Lindsay: The Management and Control of Quality, 6th edition, South Western College Pub., 2004.
5.    E.L. Grant, and R.S. Leavenworth: Statistical Quality Control, 7th edition, McGraw-Hill, 1996.
6.    J.M. Juran: Juran’s Quality Handbook, 6th edition, McGraw-Hill, 2000.
7.    J.M. Juran, and F.M. Gryna: Quality Planning and Analysis, 3rd edition, McGrawHill, 1993. 
8.    T. Pyzdek: The Six Sigma Handbook, 4th edition, McGraw-Hill, 2014.
9.    P.J. Ross: Taguchi Techniques for Quality Engineering, 2rd edition, McGraw-Hill, 1995.
10.  G. Taguchi: Introduction to Quality Engineering, Asian Productivity Organization, 1986.
11.  H.M. Wadsworth: Modern Method for Quality Control and Improvement, 2nd edition, John Wiley & Sons, 2002
 
Journals and Magazines:
1.     International Journal of Operations and Production Management, Emerald.
2.     International Journal of Production Research, Taylor and Francis.
3.     International Journal of Production Economics, Elsevier.
4.     Journal of Quality Technology, American Society for Quality.
5.     Quality Control and Applied Statistics, Executive Sciences Institute.
6.     Technometrics, Taylor and Francis.

Others: Lecture Notes
 
Time Distribution and Study Load:
Lecture hours:               45hours
Group project:               15hours
Home assignments/Self-study: 120hours
 
Teaching and Learning Methods:
The teaching is done via lectures by the instructor. The learning method includes individual assignments and group project.
 
Evaluation Scheme:
Mid-semester examination 30%, assignments and group projects 20%, final examination 50%. All examinations are open-book.

In final grading, an “A” would be awarded if a student shows a deep understanding of the knowledge learned through home assignments, project works, and exam results. A “B” would be awarded if a student shows an overall understanding of all topics. A “C” would be given if a student meets below average expectation in understanding and application of basic knowledge. A “D” would be given if a student does not meet expectations in both understanding and application of the given knowledge.
 
Instructor(s):
SECTION NAME