Glencoe Science: The Nature of Matter, Student Edition

Quality Engineering Handbook, Second Edition......Page 1
Preface and Acknowledgements......Page 6
Contents......Page 7
I.A PROFESSIONAL CONDUCT AND ASQ CODE OF ETHICS......Page 10
WHAT STRATEGIC PLANNING IS NOT......Page 12
WHAT STRATEGIC PLANNING IS......Page 13
FORMAL APPROACHES TO STRATEGIC PLANNING......Page 14
PLAN FORMATION......Page 16
PROPOSED SOLUTIONS TO THE STRATEGIC PLANNING PROBLEM......Page 17
STRATEGIC PROGRAMMING......Page 18
WHEN TO USE STRATEGIC PROGRAMMING......Page 19
THE STRATEGIC APPROACH TO QUALITY......Page 21
DEPLOYMENT OF GOALS......Page 23
PROJECT MANAGEMENT......Page 25
USEFUL PROJECT MANAGEMENT TOOLS AND TECHNIQUES......Page 26
PLANNING......Page 27
PROJECT DECOMPOSITION......Page 28
INTEGRATED QUALITY INITIATIVES......Page 29
Work breakdown structures......Page 30
FEEDBACK LOOPS......Page 32
Gantt charts......Page 33
PERT-CPM-type project management systems......Page 34
Constructing PERT-CPM network charts......Page 35
Example of PERT......Page 38
Finding the critical path......Page 39
Control and prevention of schedule slippage......Page 43
Resource conflicts......Page 44
Cost considerations in project scheduling......Page 45
Other performance measurement methodology......Page 48
RELEVANT STAKEHOLDERS......Page 49
The benchmarking process......Page 50
Getting started with benchmarking......Page 51
Why benchmarking efforts fail......Page 52
Some dangers of benchmarking......Page 54
Internal roadblocks......Page 55
Individual barriers to change......Page 56
Ineffective management support strategies......Page 58
Effective management support strategies......Page 59
SHORT-TERM (TACTICAL) PLANS......Page 60
CROSS-FUNCTIONAL COLLABORATION......Page 61
CONTINUOUS REVIEW AND ENHANCEMENT OF QUALITY PROCESS......Page 62
DOCUMENTATION AND PROCEDURES......Page 63
ELEMENTS OF A QUALITY INFORMATION SYSTEM......Page 64
SCOPE AND OBJECTIVES OF A QUALITY INFORMATION SYSTEM......Page 65
TECHNIQUES FOR ASSURING DATA ACCURACY AND INTEGRITY......Page 66
Inputs......Page 67
Off-line analysis......Page 68
Decision aids......Page 69
Presentation aids......Page 70
Research......Page 71
MASLOWS HIERARCHY OF NEEDS......Page 72
HERZBERG\'S HYGIENE THEORY......Page 73
MANAGEMENT STYLES......Page 74
Role of a manager of people......Page 75
Judgmental management style......Page 76
Combination data-based/judgment management style......Page 77
Autocratic management style......Page 78
Management By Wandering Around......Page 79
Fourth generation management......Page 80
CONFLICT RESOLUTION......Page 81
TEAM FORMATION AND EVOLUTION......Page 82
WORK GROUPS......Page 83
Quality circles......Page 84
WHEN TO USE AN OUTSIDE FACILITATOR......Page 85
SELECTING A FACILITATOR......Page 86
PRINCIPLES OF TEAM LEADERSHIP AND FACILITATION......Page 87
FACILITATING THE GROUP TASK PROCESS......Page 88
FACILITATING THE GROUP MAINTENANCE PROCESS......Page 89
TEAM DYNAMICS MANAGEMENT, INCLUDING CONFLICT RESOLUTION......Page 90
STAGES IN GROUP DEVELOPMENT......Page 91
COMMON PROBLEMS......Page 92
Productive group roles......Page 93
Counter-productive group roles......Page 95
PERFORMANCE EVALUATION......Page 96
RECOGNITION AND REWARD......Page 97
Principles of effective reward systems......Page 99
I.E TRAINING......Page 100
TRAINING NEEDS ANALYSIS......Page 101
Principles of effective communication......Page 102
Criteria for effective communication......Page 103
Lesson plans......Page 104
Example of a lesson plan......Page 105
Preparing the presentation......Page 108
Visual aids......Page 109
Post-training evaluation and reinforcement......Page 111
Evaluation......Page 112
Reinforcement......Page 114
Refreshers......Page 115
I.F COST OF QUALITY......Page 116
GOAL OF QUALITY COST SYSTEM......Page 118
ACCOUNTING SUPPORT......Page 120
MANAGEMENT OF QUALITY COSTS......Page 121
COST OF QUALITY EXAMPLES......Page 122
QUALITY COST BASES......Page 125
QUALITY COST TREND ANALYSIS......Page 127
USE OF QUALITY COSTS......Page 128
I.G QUALITY PHILOSOPHIES AND APPROACHES (e.g., JURAN, DEMING, TAGUCHI, ISHIKAWA)......Page 129
THE INSPECTION ERA......Page 130
THE QUALITY CONTROL ERA......Page 131
THE QUALITY ASSURANCE ERA......Page 133
STRATEGIC QUALITY MANAGEMENT......Page 135
Demings 14 Points......Page 136
INTEGRATION OF QUALITY INTO SELF-DIRECTED SYSTEMS......Page 138
FUNDAMENTAL PRINCIPLES OF QUALITY......Page 139
DEFINITIONS OF QUALITY......Page 140
I.H CUSTOMER RELATIONS, EXPECTATIONS, NEEDS, AND SATISFACTION......Page 141
QUALITY FUNCTION DEPLOYMENT......Page 142
CUSTOMER RELATIONSHIP MANAGEMENT AND COMMITMENT......Page 146
Complaints......Page 148
PARTNERSHIP AND ALLIANCES BETWEEN CUSTOMERS AND SUPPLIERS*......Page 149
Joint technological planning......Page 150
Keiretsu......Page 151
Strategies for communicating with customers......Page 152
Surveys......Page 153
Response types......Page 154
Survey development case study......Page 157
Focus group disadvantages......Page 163
Other customer information systems......Page 164
Multiple-customer relations......Page 165
CUSTOMER RETENTION/LOYALTY......Page 166
Complaint handling......Page 168
I.I SUPPLIER RELATIONS AND MANAGEMENT METHODOLOGIES......Page 169
VENDOR QUALITY SYSTEMS......Page 171
EVALUATING VENDOR QUALITY CAPABILITY......Page 172
VENDOR QUALITY PLANNING......Page 174
POST-AWARD SURVEILLANCE......Page 175
VENDOR RATING SCHEMES......Page 176
PROBLEMS AND PITFALLS OF VENDOR RATING SCHEMES......Page 177
QUALITY RECORDS......Page 178
PROCUREMENT STANDARDS AND SPECIFICATIONS*......Page 180
QUALITY FUNCTION MISSION......Page 181
JURAN\'S QUALITY TRILOGY......Page 183
PRIORITY OF THE QUALITY FUNCTION WITHIN THE ORGANIZATION......Page 184
QUALITY AND BUSINESS PERFORMANCE......Page 185
Assessment metrics......Page 186
FORMULATION OF QUALITY PRINCIPLES AND POLICIES......Page 188
RESOURCE REQUIREMENTS TO MANAGE THE QUALITY FUNCTION......Page 190
QUALITY ORGANIZATION......Page 193
WORK ELEMENTS IN THE QUALITY SYSTEM......Page 194
TQS MEASUREMENT SYSTEMS......Page 196
TQS FEEDBACK......Page 197
IMPROVEMENT......Page 198
II.B DOCUMENTATION SYSTEMS......Page 199
WORK INSTRUCTIONS......Page 200
CONFIGURATION CONTROL......Page 202
PRIORITY OF CHANGES......Page 203
II.C DOMESTIC AND INTERNATIONAL STANDARDS AND SPECIFICATIONS......Page 204
ISO 9000 REGISTRATION......Page 208
OTHER QUALITY STANDARDS......Page 209
AUDIT STANDARDS......Page 211
Product audits......Page 212
Systems audit......Page 214
Third-party audits......Page 216
AUDITOR QUALIFICATIONS......Page 217
SCHEDULING OF AUDITS......Page 218
STEPS IN CONDUCTING AN AUDIT......Page 219
AUDIT REPORTING PROCESS......Page 220
POST-AUDIT ACTIVITIES (E.G., CORRECTIVE ACTION, VERIFICATION)......Page 222
Quality audit versus quality survey......Page 223
III.A PROCESSES FOR PLANNING PRODUCT AND SERVICE DEVELOPMENT......Page 224
DESIGN REVIEW AND QUALIFICATION......Page 225
PROCESS QUALIFICATION AND VALIDATION METHODS......Page 226
Reading standard engineering drawings and blueprints......Page 227
The language of lines......Page 229
Geometric dimensioning and tolerancing......Page 233
Schematics......Page 237
Sample quality manual entry......Page 238
CUSTOMER-SUPPLIED MATERIALS......Page 239
Sample quality manual entry......Page 240
Sample quality manual entry......Page 241
Case study of lot traceability implementation......Page 242
Discussion of lot traceability case study......Page 244
Types of samples......Page 245
Deviations and waivers......Page 246
Sample quality manual entry......Page 247
Example of an MRB procedure......Page 248
GENERAL COMMENTS ON ACCEPTANCE SAMPLING......Page 249
DEFINITIONS......Page 250
GENERAL THEORY......Page 251
OPERATING CHARACTERISTICS CURVE (OC CURVE)......Page 252
Instructions for using worksheet......Page 253
Example of evaluating an acceptance sampling plan......Page 255
Discussion of sampling plan evaluation......Page 256
Double sampling plan......Page 257
Sequential sampling plan......Page 258
Deming\'s all—or—none rule......Page 259
How to use ANSI/ASQ Z1.4......Page 260
SAMPLING PLANS: ANSI/ASQ Z1.9......Page 261
DEFINITIONS......Page 263
DESTRUCTIVE TESTING......Page 267
NON-DESTRUCTIVE TESTING......Page 268
MECHANICAL INSPECTION*......Page 271
Precision instruments......Page 272
Micrometers......Page 274
Indicator gages......Page 276
Gage blocks......Page 277
Other gaging......Page 279
Direct reading vs. differential measurements......Page 282
Measurement system discrimination......Page 283
Bias......Page 285
Example of computing bias......Page 286
Example of estimating repeatability......Page 287
Reproducibility example (AIAG method)......Page 289
Reproducibility example (alternative method)......Page 290
Part-to-part variation......Page 291
Example of measurement system analysis summary......Page 292
Linearity example......Page 293
Traceability to standards......Page 295
Measurement error......Page 296
Calibration systems......Page 297
Control system......Page 299
Control of standard integrity......Page 300
RELIABILITY TERMS......Page 302
IV.B RELIABILITY LIFE CHARACTERISTIC CONCEPTS......Page 303
IV.C DESIGN OF SYSTEMS FOR RELIABILITY......Page 304
RELIABILITY APPORTIONMENT......Page 305
SERIES......Page 306
PARALLEL......Page 307
REDUNDANT......Page 308
SEVEN STEPS IN PREDICTING DESIGN RELIABILITY......Page 309
SAFETY......Page 310
EXAMPLE OF COMPUTING PROBABILITY OF FAILURE......Page 311
Solution......Page 312
MAINTAINABILITY AND AVAILABILITY*......Page 313
QUANTIFYING MAINTAINABILITY AND AVAILABILITY......Page 315
PREVENTIVE MAINTENANCE......Page 322
DESIGNING FOR MAINTAINABILITY......Page 328
SYSTEM EFFECTIVENESS......Page 329
PRODUCT TRACEABILITY SYSTEMS AND RECALL PROCEDURES......Page 330
IV.E RELIABILITY FAILURE ANALYSIS AND REPORTING*......Page 331
RECORDING, REPORTING, AND PROCESSING......Page 332
Failure terms and definitions......Page 334
Failure categories......Page 335
How will data be collected and reported......Page 337
Who will collect the information......Page 338
What level of accuracy is needed......Page 339
CORRECTIVE ACTION AND FOLLOW-UP......Page 340
DESIGN REVIEW......Page 341
Fault-tree construction......Page 342
Cut sets and path sets......Page 345
Quantitative fault tree analysis......Page 349
Solution......Page 350
CRITICALITY ANALYSIS......Page 352
The qualitative approach to FMECA......Page 353
FMECA quantitative approach......Page 354
FMECA process......Page 356
Steps for completing the form......Page 358
FMECA follow-up report......Page 359
What it takes to do a successful FMECA......Page 361
ENVIRONMENTAL REQUIREMENTS AND INFLUENCE......Page 362
DIFFERENCES BETWEEN PART FUNCTION, PART FAILURE MECHANISM, FAILURE EFFECT, FAILURE DETECTION, AND FAILURE MODE......Page 363
Process elements......Page 367
Process control......Page 368
KAIZEN......Page 369
Resynthesis of disaggregated work......Page 372
Cycle-time measurements......Page 373
Identifying the need to improve cycle-time......Page 374
Causes of long cycle-times......Page 375
Results......Page 377
PDCA (PLAN-DO-CHECK-ACT)......Page 378
AFFINITY DIAGRAMS......Page 382
PROCESS DECISION PROGRAM CHARTS......Page 384
MATRIX DIAGRAMS......Page 385
INTERRELATIONSHIP DIGRAPHS......Page 386
Combination ID/matrix method......Page 387
Consensus criteria method......Page 388
ACTIVITY NETWORK DIAGRAMS......Page 389
Nominal group technique......Page 390
Force-field analysis......Page 391
How to perform a Pareto analysis......Page 393
Example of Pareto analysis......Page 394
CAUSE AND EFFECT DIAGRAMS......Page 395
FLOW CHARTS......Page 398
Statistical process control principles......Page 400
Distributions......Page 403
Process control versus meeting requirements......Page 404
CHECK SHEETS......Page 406
Defect check sheets......Page 407
Defect location check sheet......Page 408
How to construct a scatter diagram......Page 409
Example of a scatter diagram......Page 410
Pointers for using scatter diagrams......Page 412
HISTOGRAMS......Page 413
How to construct a histogram......Page 414
Histogram example......Page 415
Pointers for using histograms......Page 418
V.D CORRECTIVE ACTION......Page 419
V.E PREVENTIVE ACTION......Page 420
Inadvertent errors......Page 421
Technique errors......Page 422
Willful errors (sabotage)......Page 423
V.F OVERCOMING BARRIERS TO QUALITY IMPROVEMENT......Page 424
MANAGING CHANGE......Page 425
ROLES......Page 426
Goals......Page 427
Mechanisms used by change agents......Page 428
Change networks......Page 430
Transforming staff functions......Page 431
ENUMERATIVE AND ANALYTICAL STUDIES......Page 433
What are enumerative and analytic studies?......Page 435
CENTRAL LIMIT THEOREM......Page 436
Random variables......Page 437
Sets......Page 438
Probability functions......Page 439
Methods of enumeration......Page 440
Example of expectation......Page 441
The mean, variance, and standard deviation as expectations......Page 442
Example: finding the variance for a fair die......Page 443
LEVELS OF MEASUREMENT......Page 444
DESCRIPTIVE STATISTICS......Page 446
Stem-and-leaf plots......Page 450
Boxplots......Page 452
VI.C PROPERTIES AND APPLICATIONS OF PROBABILITY DISTRIBUTIONS......Page 454
SAMPLING DISTRIBUTIONS......Page 455
Discrete pdfs and cdfs......Page 457
Continuous pdfs and cdfs......Page 458
Continuous cdfs......Page 459
Binomial distribution......Page 460
Example of applying the Poisson distribution......Page 461
Hypergeometric distribution......Page 462
Normal distribution......Page 463
Example of calculating (A, (J2 and (J......Page 464
Example of calculating Z......Page 465
Exponential distribution......Page 466
Example of using the exponential cdf......Page 467
Chi-Square......Page 468
Student\'s t distribution......Page 469
F distribution......Page 470
VI.D STATISTICAL DECISION-MAKING......Page 471
Estimates of the mean......Page 472
Example: estimating JH when <7 is unknown......Page 473
Hypothesis testing......Page 474
Example: hypothesis test of sample mean......Page 475
Example: hypothesis test of a standard deviation compared to a standard value......Page 476
PAIRED COMPARISONS*......Page 477
Example: capacity of batteries......Page 478
GOODNESS OF FIT TESTS......Page 479
Example of a one-way ANOVA......Page 483
ANOVA procedure......Page 484
Performing ANOVA manually......Page 485
Example of chi-square test......Page 486
LINEAR MODELS......Page 487
LEAST-SQUARES FIT......Page 493
Example of regression analysis......Page 495
CORRELATION ANALYSIS......Page 497
How to prepare and analyze run charts......Page 499
Run length......Page 500
Number of runs......Page 502
Trends......Page 503
Pointers for using run charts......Page 504
Testing for autocorrelation......Page 505
Example of serial correlation analysis*......Page 507
First differences procedure......Page 509
Example......Page 510
Overall plot of residuals......Page 511
THE TRADITIONAL APPROACH VS. STATISTICALLY DESIGNED EXPERIMENTS......Page 513
Definitions......Page 514
POWER AND SAMPLE SIZE......Page 515
DESIGN CHARACTERISTICS......Page 516
TYPES OF DESIGNS......Page 517
Example of two way Anova with no replicates......Page 519
Example of two way ANOVA with replicates......Page 521
Analyzing factorial experiments......Page 523
Example of Yates method......Page 525
EMPIRICAL MODEL BUILDING AND SEQUENTIAL LEARNING......Page 526
\"Where are we anyway?\"......Page 528
\"What\'s important here?\"......Page 529
\"Which way is up?\"......Page 532
PHASE III: THE FACTORIAL EXPERIMENT......Page 534
Fractional factorial fit......Page 536
PHASE IV: THE COMPOSITE DESIGN......Page 537
PHASE V: ROBUST PRODUCT AND PROCESS DESIGN......Page 541
Introduction......Page 542
Distributions......Page 545
Central limit theorem......Page 546
Prevention versus detection......Page 547
COMMON AND SPECIAL CAUSES OF VARIATION*......Page 549
Subgroup equations for average and range charts......Page 553
Control limit equations for averages charts using R-bar......Page 554
Example of averages and ranges control charts......Page 555
Subgroup equations for average and sigma charts......Page 557
Control limit equations for averages charts based on s-bar......Page 558
Example of averages and standard deviation control charts......Page 559
Control limit equations for individuals charts......Page 562
Example of individuals and moving ranges control charts......Page 563
Analysis of p charts......Page 566
Example of p chart calculations......Page 567
Control limit equations for np charts......Page 569
Example of np chart calculation......Page 570
Control charts for average occurrences-per-unit (u charts)......Page 571
Control limit equations for u charts......Page 572
Example of u chart......Page 573
Control limit equations for c charts......Page 575
Example of c chart......Page 576
Variable selection: preparing the process control plan......Page 578
Control chart selection......Page 580
Rational subgroup sampling......Page 581
Control charts interpretation......Page 582
Mixture example #2......Page 587
Rules for determining statistical control: run tests......Page 588
Tampering effects and diagnosis......Page 590
Strategies for short and small runs......Page 592
Preparing the short-run Process Control Plan (PCP)......Page 593
Selecting process control elements......Page 594
The single part process......Page 596
Other elements of the PCP......Page 597
Variables data......Page 598
Stage one: find the process......Page 599
Setup approval procedure......Page 600
Code value charts......Page 602
Stabilized control charts for variables......Page 605
Attribute SPC for small and short runs......Page 609
Stabilized attribute control charts......Page 610
Demerit control charts......Page 614
Simplified quality score charts......Page 616
PRE-CONTROL......Page 617
Setting up PRE-Control......Page 618
Using PRE-Control......Page 619
VI.H ANALYZING PROCESS CAPABILITY......Page 620
HOW TO PERFORM A PROCESS CAPABILITY STUDY......Page 621
Control chart method: variables data......Page 623
PROCESS CAPABILITY INDEXES......Page 624
INTERPRETING CAPABILITY INDEXES......Page 625
EXAMPLE OF CAPABILITY ANALYSIS USING NORMALLY DISTRIBUTED VARIABLES DATA......Page 627
DISCUSSION......Page 628
MOTOROLA\'S SIX SIGMA PROGRAM......Page 629
PROCESS PERFORMANCE INDICES......Page 630
I. MANAGEMENT AND LEADERSHIP IN QUALITY ENGINEERING......Page 632
II. QUALITY SYSTEMS DEVELOPMENT, IMPLEMENTATION, AND VERIFICATION (19 Questions)......Page 633
III. PLANNING, CONTROLLING, AND ASSURING PRODUCT AND PROCESS QUALITY (33 Questions)......Page 634
IV. RELIABILITY AND RISK MANAGEMENT (11 Questions)......Page 635
V. PROBLEM SOLVING AND QUALITY IMPROVEMENT (25 Questions)......Page 636
VI. QUANTITATIVE METHODS (53 Questions)......Page 637
SIX LEVELS OF COGNITION BASED ON BLOOM\'S TAXONOMY (1956)......Page 641
APPENDIX 2: Quality Auditing Terminology......Page 643
APPENDIX 3: Glossary of Basic Statistical Terms*......Page 652
APPENDIX 4: Area Under the Standard Normal Curve......Page 658
APPENDIX 5: Critical values of the t-Distribution......Page 661
APPENDIX 6: Chi-Square Distribution......Page 663
APPENDIX 7: F Distribution (a= 1%)......Page 666
APPENDIX 8: F Distribution (a = 5%)......Page 668
APPENDIX 9: Poisson Probability Sums......Page 670
APPENDIX 10: Tolerance Interval Factors......Page 673
APPENDIX 11: Durbin-Watson Test Bounds......Page 676
APPENDIX 12: y Factors for Computing AOQL......Page 679
APPENDIX 13: Control Chart Constants......Page 680
APPENDIX 14: Control Chart Equations......Page 682
APPENDIX 15: Mil-Std-45662 Military Standard: Calibration System Requirements......Page 684
1. SCOPE......Page 685
4. GENERAL STATEMENTS OF REQUIREMENTS......Page 686
5. DETAILED STATEMENTS OF REQUIREMENTS......Page 687
6. MISCELLANEOUS......Page 690
APPENDIX 16: Table of d2 Values......Page 692
APPENDIX 17: Power Functions for ANOVA......Page 694
APPENDIX 18: Factors for Short Run Control Charts......Page 699
APPENDIX 19: Significant Number of Consecutive Highest or Lowest Values from One Stream of a Multiple-Stream Process......Page 701
APPENDIX 20: Beta Table Values of Reliability......Page 702
References......Page 705