Quality Assurance

QUALITY ASSURANCE (CUTM1082)

(Credits: 1-1-0)

COURSE OBJECTIVES

• To introduce the concept of SQC
• To understand Design of Experiments concept and ANOVA test
• To learn about the different plots in quality control

COURSE OUTCOMES

The student should be able to:
• Understand quality function deployment principles
• Understand concept of Failure mode affect analysis and apply it in product design process.
• Carry out statistical analysis of experiment, ANOVA ratio test and apply advanced DOE method for product testing.
• Understand statistical process control techniques and reliability concepts.
• Understand SIX SIGMA process and lean production concept.
• Prepare Pareto diagrams, cause and effect diagrams, matrix plots and 3-D plots.

SYLLABUS

MODULE - I (Design for Quality) (1 hr)

Quality Function Deployment, Objectives and functions, Design process, controlling factors in design process.

MODULE - II (Failure Mode Effect Analysis (FMEA)) (3 hrs)

Basic methods: Refining geometry and layout, general process of product embodiment, embodiment checklists, FMEA method.

Practice - 1: Performing a FMEA of a Wooden Chair.

MODULE - III (Design of Experiments (DOE)) (4 hrs)

Design of Experiments: Basic methods, two factorial experiments, orthogonality, Base design method, higher factorial experiments.

Practice - 2: Design of Experiments for comfort conditions in a room using Minitab.

MODULE - IV (Analysis of Variance (ANOVA)) (4 hrs)

Statistical analysis of experiments, degree of freedom, correlation coefficient, ANOVA test, residual plots.

Practice - 3: Performing ANOVA to know the significance of influencing parameters for comfort conditions in a room using Minitab.

MODULE - V (Statistical Process Control (SPC)) (2 hrs)

Frequency distributions and histograms, Pareto diagrams, Probability distribution, Matrix plots and 3D plots.

MODULE - VI (Reliability) (4 hrs)

Reliability – Survival and Failure, series and parallel systems, mean time between failure, mean time to repair.

Practice - 4: Determining the reliability of series and parallel systems.

MODULE - VII (Design of Six Sigma) (4 hrs)

Basics of six sigma, project selection for six sigma, six sigma problem solving, six sigma and lean production.

Practice - 5: Determining the six sigma limits during machining a cylindrical work piece on CNC lathe.

TEXTBOOKS

1. Stastical Quality Control, M. Mahajan, Khanna Publisher.
2. Reliability Engineering, L.S. Srinath, Affiliated East West Press.

REFERENCE BOOKS

1. Robust Design for Quality Engineering and Six Sigma, Sung H. Park, World Scientific Publisher.

SESSION PLAN

Session - 1 (1 hr)

Quality Function Deployment, Objectives and functions, Design process, controlling factors in design process.

Link - CONCEPT OF QUALITY

Link - CONCEPT OF QUALITY CONTROL

Link - CONCEPT OF QUALITY ASSURANCE

Session - 2 (1 hr)

Basic methods: Refining geometry and layout, general process of product embodiment, embodiment checklists, FMEA method.

Link - FMEA CONCEPT

Session - 3 (2 hrs)

Practice - 1: Performing a FMEA of a Wooden Chair.

Session - 4 (2 hrs)

Design of Experiments: Basic methods, two factorial experiments, orthogonality, Base design method, higher factorial experiments.

Link - DOE CONCEPT

Session - 5 (2 hrs)

Practice - 2: Design of Experiments for comfort conditions in a room using Minitab.

Session - 6 (2 hrs)

Statistical analysis of experiments, degree of freedom, correlation coefficient, ANOVA test, residual plots. (2 hrs)

Link - ANOVA CONCEPT

Session - 7 (2 hrs)

Practice - 3: Performing ANOVA to know the significance of influencing parameters for comfort conditions in a room using Minitab.

Session - 8 (2 hrs)

Frequency distributions and histograms, Pareto diagrams, Probability distribution, Matrix plots and 3D plots.

Link - CONCEPT OF SPC

Session - 9 (2 hrs)

Reliability – Survival and Failure, series and parallel systems, mean time between failure, mean time to repair.

Link - CONCEPT OF RELIABILITY

Link - RELIABILITY OF SERIES AND PARALLEL SYSTEMS

Session - 10 (2 hrs)

Practice - 4: Determining the reliability of series and parallel systems.

Session - 11 (2 hrs)

Basics of six sigma, project selection for six sigma, six sigma problem solving, six sigma and lean production.

Link - CONCEPT OF SIX SIGMA

Link - CONCEPT OF LEAN MANUFACTURING

Session - 12 (2 hrs)

Practice - 5: Determining the six sigma limits during machining a cylindrical work piece on CNC lathe.