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Chapter 10 Classroom
Chapter 10 Classroom
Quality Control
Operations Management
William J. Stevenson
8th edition
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CHAPTER
10
Quality Control
McGraw-Hill/Irwin
Operations Management, Eighth Edition, by William J. Stevenson Copyright 2005 by The McGraw-Hill Companies, Inc. All rights reserved.
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Figure 10.1
Inspection and corrective action during production
Process control
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Inspection
Figure 10.2
Acceptance sampling
Process control
Acceptance sampling
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Inspection Costs
Figure 10.3
Cost
Total Cost
Cost of inspection
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Raw materials and purchased parts Finished products Before a costly operation Before an irreversible process Before a covering process
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Table 10.1
Type of business Fast Food Inspection points Cashier Counter area Eating area Building Kitchen Hotel/motel Parking lot Accounting Building Main desk Supermarket Cashiers Deliveries
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Control Chart
Control Chart
A time ordered plot representative sample statistics obtained from an on going process (e.g. sample means)
Upper and lower control limits define the range of acceptable variation
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Control Chart
Out of control
Figure 10.4
Abnormal variation due to assignable sources
UCL
Mean Normal variation due to chance Abnormal variation due to assignable sources
LCL
10 11 12 13 14 15
Sample number
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The essence of statistical process control is to assure that the output of a process is random so that future output will be random.
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Random variation: Natural variations in the output of a process, created by countless minor factors Assignable variation: A variation whose source can be identified
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Sampling Distribution
Sampling distribution Process distribution
Figure 10.5
Mean
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Normal Distribution
Figure 10.6
Standard deviation
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Control Limits
Sampling distribution Process distribution
Figure 10.7
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X bar charts
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Figure 10.10A
Sampling Distribution
UCL
x-Chart
LCL
Detects shift
UCL
R-chart
LCL
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Figure 10.10B
Sampling Distribution
UCL
x-Chart
LCL
UCL
R-chart
LCL
Reveals increase
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c-Chart - Control chart used to monitor the number of defects per unit
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Use of p-Charts
Table 10.3
Good or bad
Pass or fail Operate or dont operate
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Use of c-Charts
Table 10.3
Use only when the number of occurrences per unit of measure can be counted; nonoccurrences cannot be counted.
Scratches, chips, dents, or errors per item Cracks or faults per unit of distance Breaks or Tears per unit of area Bacteria or pollutants per unit of volume Calls, complaints, failures per unit of time
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Variables
Attributes
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Process Capability
Tolerances or specifications
Process variability
Process capability
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Process Capability
Upper Specification
Figure 10.15
Lower Specification
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specification width Process capability ratio, Cp = process width Cp = Upper specification lower specification 6
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Lower specification
1350 ppm 1.7 ppm
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1.
2.
3.
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Are named according to the statistics being plotted, i.e., X bar, R, p, and c Have a center line that is the overall average Have limits above and below the center line at 3 standard deviations (usually)
Upper Control Limit (UCL)
Center line
Lower Control Limit (LCL)
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Process Centering
X
i 1
R max( X i ) min( X i )
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X bar charts
Center line is the grand mean (X double bar) m Points are X bars
x / n
UCL X z x
-OR-
X
j 1
LCL X z x
UCL X A2 R
LCL X A2 R
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R Charts
Center line is the grand mean (R bar) Points are R D3 and D4 values are tabled according to n (sample size)
UCL D4 R
LCL D3 R
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Charts are always used in tandem Data are collected (20-25 samples) Sample statistics are computed All data are plotted on the 2 charts Charts are examined for randomness If random, then limits are used forever
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Attribute Charts
c
i 1
UCL c z c
centerline
LCL c z c
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Attribute Charts
pi
x
i 1
p
j 1
x
ij
nm
centerline
p (1 p ) UCL p z n
p (1 p ) LCL p z n
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Process Capability
Text
Text
Text
Text
Text
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Lower
Title
+1 +2 +3
Upper
Spec
Spec
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Training
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Quality Measurement
STA10 Monitoring
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Services/Measurement