Introduction to Statistical

Quality Control, 4th Edition

Douglas C. Montgomery
Arizona State University

Introduction to Statistical Quality Control,

4th Edition
 Chapter 1
Quality Improvement in the
Modern Business Environment

Introduction to Statistical Quality Control,

4th Edition
1-1. The Meaning of Quality and
Quality Improvement

1-1.1 Dimensions of Quality

1-1.2 Quality Engineering Technology

Introduction to Statistical Quality Control,

4th Edition
1-1.1 Dimensions of Quality

• Performance • Aesthetics
• Reliability • Features
• Durability • Perceived Quality
• Serviceability • Conformance to
standards

Introduction to Statistical Quality Control,

4th Edition
1-1.1 Dimensions of Quality
• Definitions of Quality

Quality means fitness for use

- quality of design
- quality of conformance
Quality is inversely proportional to
variability.

Introduction to Statistical Quality Control,

4th Edition
1-1.1 Dimensions of Quality

• Quality Improvement
Quality improvement is the reduction of
variability in processes and products.

Alternatively, quality improvement is also

seen as “waste reduction”.

Introduction to Statistical Quality Control,

4th Edition
1-1.1 Dimensions of Quality –
Transmission Example

Introduction to Statistical Quality Control,

4th Edition
1-1.2 Quality Engineering
Terminology

Quality Characteristics

• Physical - length, weight, voltage, viscosity

• Sensory - taste, appearance, color
• Time Orientation - reliability, durability,
serviceability
Introduction to Statistical Quality Control,
4th Edition
1-1.2 Quality Engineering
Terminology

Quality engineering is the set of operational,

managerial, and engineering activities that a
company uses to ensure that the quality
characteristics of a product are at the
nominal or required levels.

Introduction to Statistical Quality Control,

4th Edition
1-1.2 Quality Engineering
Terminology

Two types of data

• Attributes Data - discrete data, often in the

form of counts.

• Variables Data - continuous measurements

such as length, weight.
Introduction to Statistical Quality Control,
4th Edition
1-1.2 Quality Engineering
Terminology
Specifications
Quality characteristics being measured are
often compared to standards or
specifications.
• Nominal or target value
• Upper Specification Limit (USL)
• Lower Specification Limit (LSL)
Introduction to Statistical Quality Control,
4th Edition
1-1.2 Quality Engineering
Terminology
• When a component or product does not
meet specifications, they are considered to
be nonconforming.
• A nonconforming product is considered
defective if it has one or more defects.
• Defects are nonconformities that may
seriously affect the safe or effective use of
the product.
Introduction to Statistical Quality Control,
4th Edition
1-1.2 Quality Engineering
Terminology
• Concurrent Engineering
Team approach to design. Specialists from
manufacturing, quality engineering,
management, etc. work together for product
or process improvement.

Introduction to Statistical Quality Control,

4th Edition
1-2. A Brief History of Quality
Control and Improvement
(Refer to Table 1-1)
• Walter Shewhart (1924) introduced statistical
control chart concepts.
• The American Society for Quality Control formed
in 1946 (now known as the American Society for
Quality (ASQ)).
• 1950s and 1960s saw an increase in reliability
engineering, experimental design, and statistical
quality control
Introduction to Statistical Quality Control,
4th Edition
1-2. A Brief History of Quality
Control and Improvement
(Refer to Table 1-1)
• Competition from foreign industries (Japan)
increases during the 1970s and 1980s.
• Statistical methods for quality improvement use
increases in the United States during the 1980s
• Total Quality Management (TQM) emerges
during 1970s and into the 1980s as an important
management tool to implement statistical methods.
Introduction to Statistical Quality Control,
4th Edition
1-2. A Brief History of Quality
Control and Improvement

• Malcolm Baldridge National Quality Award is

established in 1988.
• ISO 9000 certification activities increase in U.S.
industry in the 1990s.
• Motorola’s Six-Sigma initiative begins in the
1990s.

Introduction to Statistical Quality Control,

4th Edition
1-3. Statistical Methods for
Quality Control and Improvement

Three major areas:

• Statistical process control (SPC)

• Design of experiments (DOX)
• Acceptance sampling

Introduction to Statistical Quality Control,

4th Edition
1-3. Statistical Methods for
Quality Control and Improvement

Statistical Process
Control (SPC)
• Control charts are used
for process monitoring
and variability
reduction.
• SPC is an on-line
quality control tool.
Introduction to Statistical Quality Control,
4th Edition
1-3. Statistical Methods for
Quality Control and Improvement

Design of Experiments
• Experimental design is an approach to
systematically varying the controllable input
factors in the process and determine the effect
these factors have on the output responses.
• Experimental designs are off-line quality tools.
• Crucial for variability reduction.

Introduction to Statistical Quality Control,

4th Edition
1-3. Statistical Methods for
Quality Control and Improvement
Acceptance Sampling
• Acceptance sampling is the inspection and
classification of a sample of the product selected
at random from a larger batch or lot and the
ultimate decision about disposition of the lot.
• Two types:
1. Outgoing inspection - follows production
2. Incoming inspection - before use in
production
Introduction to Statistical Quality Control,
4th Edition
1-4. Other Aspects of Quality
Control and Improvement
Total Quality Management (TQM)
• TQM is a managerial framework to accomplish
quality improvement.
• Other names and related approaches:
– Company-Wide Quality Control (CWQC)
– Total Quality Assurance (TQA)
– Six-Sigma

Introduction to Statistical Quality Control,

4th Edition
1-4. Other Aspects of Quality
Control and Improvement
1-4.1 Quality Philosophy and Management
Strategies
1-4.2 The Link Between Quality and
Productivity
1-4.3 Quality Costs
1-4.4 Legal Aspects of Quality
1-4.5 Implementing Quality Improvement
Introduction to Statistical Quality Control,
4th Edition
1-4.1 Quality Philosophy and
Management Strategies
Three Important Leaders
• W. Edwards Deming
- Emphasis on statistical methods in quality
improvement (see Deming’s 14 points)
• Joseph Juran
- Emphasis on managerial role in quality
implementation
• Armand V. Feigenbaum
- Emphasis on organizational structure
Introduction to Statistical Quality Control,
4th Edition
1-4.1 Quality Philosophy and
Management Strategies

• Total Quality Management (TQM)

• Quality Standards and Registration
– ISO 9000
• Six Sigma
• Just-In-Time, Lean Manufacturing,
Poka-Yoke, etc.
Introduction to Statistical Quality Control,
4th Edition
1-4.2 The Link Between Quality
and Productivity

• Effective quality improvement can be

instrumental in increasing productivity and
reducing cost.
• The cost of achieving quality improvements
and increased productivity is often
negligible.

Introduction to Statistical Quality Control,

4th Edition
1-4.3 Quality Costs

Quality Costs are those categories of costs that are

associated with producing, identifying, avoiding,
or repairing products that do not meet
requirements. These costs are:
• Prevention Costs
• Appraisal Costs
• Internal Failure Costs
• External Failure Costs
Introduction to Statistical Quality Control,
4th Edition
1-4.4 Legal Aspects of Quality

The re-emergence of quality assurance as

an important business strategy is in
part a result of

1. Consumerism

2. Product Liability

Introduction to Statistical Quality Control,

4th Edition
1-4.5 Implementing Quality
Improvement
• Strategic Management of Quality
• Almost all successful efforts have been
management-driven.
• Too much emphasis on registration and
certification programs (ISO, QS)
– Insufficient focus on quality planning and design,
quality improvement, overemphasis on quality
assurance
– Poor use of available resources
Introduction to Statistical Quality Control,
4th Edition