PART I PHILOSOPHY AND FUNDAMENTALS 1

1 Introduction to Quality Control and the Total Quality System 3

1-1 Introduction and Chapter Objectives, 3

1-2 Evolution of Quality Control, 4

1-3 Quality, 7

1-4 Quality Control, 11

1-5 Quality Assurance, 13

1-6 Quality Circles and Quality Improvement Teams, 14

1-7 Customer Needs and Market Share, 15

1-8 Benefits of Quality Control and the Total Quality System, 16

1-9 Quality and Reliability, 17

1-10 Quality Improvement, 18

1-11 Product and Service Costing, 19

1-12 Quality Costs, 22

1-13 Measuring Quality Costs, 26

1-14 Management of Quality, 30

1-15 Quality and Productivity, 33

1-16 Total Quality Environmental Management, 36

1-17 Profile of a Company: The Bama Companies, Inc., 37

2 Some Philosophies and Their Impact on Quality 47

2-1 Introduction and Chapter Objectives, 47

2-2 Service Industries and Their Characteristics, 48

2-3 Model for Service Quality, 53

2-4 W. Edwards Deming’s Philosophy, 56

2-5 Philip B. Crosby’s Philosophy, 75

2-6 Joseph M. Juran’s Philosophy, 78

2-7 The Three Philosophies Compared, 82

3 Quality Management: Practices, Tools, and Standards 93

3-1 Introduction and Chapter Objectives, 93

3-2 Management Practices, 94

3-3 Quality Function Deployment, 103

3-4 Benchmarking and Performance Evaluation, 110

3-5 Tools for Continuous Quality Improvement, 120

3-6 International Standards ISO 9000 and

3-7 Malcolm Baldrige National Quality Award, 135

PART II STATISTICAL FOUNDATIONS AND METHODS OF QUALITY IMPROVEMENT 147

4 Fundamentals of Statistical Concepts and Techniques in Quality Control and Improvement 149

4-1 Introduction and Chapter Objectives, 149

4-2 Population and Sample, 150

4-3 Parameter and Statistic, 150

4-4 Probability, 150

4-5 Descriptive Statistics: Describing Product or Process Characteristics, 156

4-6 Probability Distributions, 173

4-7 Inferential Statistics: Drawing Conclusions on

5 Data Analyses and Sampling 229

5-1 Introduction and Chapter Objectives, 229

5-2 Empirical Distribution Plots, 229

5-3 Randomness of a Sequence, 234

5-4 Validating Distributional Assumptions, 236

5-5 Transformations to Achieve Normality, 239

5-6 Analysis of Count Data, 244

5-7 Concepts in Sampling, 247

PART III STATISTICAL PROCESS CONTROL 263

6 Statistical Process Control Using Control Charts 265

6-1 Introduction and Chapter Objectives, 265

6-2 Causes of Variation, 267

6-3 Statistical Basis for Control Charts, 267

6-4 Selection of Rational Samples, 279

6-5 Analysis of Patterns in Control Charts, 280

6-6 Maintenance of Control Charts, 284

7 Control Charts for Variables 289

7-1 Introduction and Chapter Objectives, 289

7-2 Selection of Characteristics for Investigation, 290

7-3 Preliminary Decisions, 292

7-4 Control Charts for the Mean and Range, 293

7-5 Control Charts for the Mean and Standard Deviation, 310

7-6 Control Charts for Individual Units, 315

7-7 Control Charts for Short Production Runs, 318

7-8 Other Control Charts, 321

7-9 Multivariate Control Charts, 343

8 Control Charts for Attributes 369

8-1 Introduction and Chapter Objectives, 369

8-2 Advantages and Disadvantages of Attribute Charts, 370

8-3 Preliminary Decisions, 371

8-4 Chart for Proportion Nonconforming: p-Chart, 372

8-5 Chart for Number of Nonconforming Items: np-Chart, 384

8-6 Chart for the Number of Nonconformities: c-Chart, 387

8-7 Chart for Number of Nonconformities Per Unit: u-Chart, 390

8-8 Chart for Demerits Per Unit: U-Chart, 393

8-9 Charts for Highly Conforming Processes, 396

8-10 Operating Characteristic Curves for Attribute Control Charts, 400

9 Process Capability Analysis 415

9-1 Introduction and Chapter Objectives, 415

9-2 Specification Limits and Control Limits, 416

9-3 Process Capability Analysis, 417

9-4 Natural Tolerance Limits, 419

9-5 Specifications and Process Capability, 420

9-6 Process Capability Indices, 423

9-7 Process Capability Analysis Procedures, 441

9-8 Capability Analysis for Nonnormal Distributions, 443

9-9 Setting Tolerances on Assemblies and Components, 445

9-10 Estimating Statistical Tolerance Limits of a Process, 453

PART IV ACCEPTANCE SAMPLING 465

10 Acceptance Sampling Plans for Attributes and Variables 467

10-1 Introduction and Chapter Objectives, 467

10-2 Advantages and Disadvantages of Sampling, 468

10-3 Producer and Consumer Risks, 468

10-4 Operating Characteristic Curve, 469

10-5 Types of Sampling Plans, 473

10-6 Evaluating Sampling Plans, 475

10-7 Bayes’ Rule and Decision Making Based on Samples, 480

10-8 Lot-by-Lot Attribute Sampling Plans, 483

10-9 Other Attribute Sampling Plans, 501

10-10 Deming’s kp Rule, 504

10-11 Sampling Plans for Variables, 507

10-12 Variable Sampling Plans for a Process Parameter, 508

10-13 Variable Sampling Plans for Estimating the Lot Proportion

PART V PRODUCT AND PROCESS DESIGN 527

11 Reliability 529

11-1 Introduction and Chapter Objectives, 529

11-2 Reliability, 529

11-3 Life-Cycle Curve and Probability Distributions in Modeling Reliability, 530

11-4 System Reliability, 534

11-5 Operating Characteristic Curves, 542

11-6 Reliability and Life Testing Plans, 544

12 Experimental Design and the Taguchi Method 559

12-1 Introduction and Chapter Objectives, 559

12-2 Experimental Design Fundamentals, 560

12-3 Some Experimental Designs, 565

12-4 Factorial Experiments, 585

12-5 The Taguchi Method, 613

12-6 The Taguchi Philosophy, 614

12-7 Loss Functions, 617

12-8 Signal-to-Noise Ratio and Performance Measures, 624

12-9 Critique of S/N Ratios, 627

12-10 Experimental Design in the Taguchi Method, 628

12-11 Parameter Design in the Taguchi Method, 644

12-12 Critique of Experimental Design and the Taguchi Method, 648

Appendixes 665

A-1 Cumulative Binomial Distribution, 665

A-2 Cumulative Poisson Distribution, 670

A-3 Cumulative Standard Normal Distribution, 672

A-4 Values of t for a Specified Right-Tail Area, 675

A-5 Chi-Squared Values for a Specified Right-Tail Area, 677

A-6 Values of F for a Specified Right-Tail Area, 679

A-7 Factors for Computing Center line and Three-Sigma Control Limits, 685

A-8 Uniform Random Numbers, 686

Index 687