<Course #<Prof Name>Updated 11/17/2018
Statistical Quality Control Techniques
TCMG 524 – 6R1: Statistical Quality Control Techniques
Semester: / Spring 2017 / Instructor: / Mike DonofrioCourse Number: / TCMG 524 – 6R1 / Office: / Virtual* or Classroom+
Credit Hours: / 3 / E-mail: /
Class Location: / Mandeville Room 322 / Phone: / 651-286-3523
Regular Class Time: / Thursday, 6:15 PM - 8:45 PM / Office Hours: / Sunday**
Thursday+845-915p
Friday**
byappointment
1.Course Description:
This course presents Statistical Quality Control techniques used in determining operating quality levels to maintain quality assurance in service and manufacturing industries. Topics covered will include tools for detection and isolation of sources of variation: construction and interpretation of charts for variables and attributes, process control and capability. The course objective is to develop an operational familiarity with contemporary methods found to be effective.
2.Course Pre-requisites
- Basic knowledge of probability and statistics.
- General spreadsheet and presentation software skills and familiarity with industrial engineering, operations research, and manufacturing systems
3.Course Learning Objectives:
The course objective is to develop an understanding of Statistical Quality Control, and applications to in a variety of situations. Continuous process improvement methodologies and techniques will be covered and applied to real life examples.
The objectives of the course are to demonstrate:
- A comprehensive understanding of the modern statistical methods for quality control and improvement.
- An understating of preventing, detecting, and analyzing the root cause of problems in manufacturing and service industries with the intended outcome of eliminating them for- ever.
- Learn quality management best practices by reviewing current and emerging quality industry standards and practices as suggested by the American Society for Quality (ASQ), ISO 9000, recognized Lean Six Sigma methodology,etc.
4.Course Topics
- Introduction to basic concepts of quality improvemen, quality management, and quality control
- An overview of Statistical Quality Control concepts and methods
- Six-Sigma Process and the DMAIC Roadmap
- Industrial Quality applications and examples
- Detecting problems: Statistical Process Control and Capability
- Root cause analysis, methods and examples
- Qualitative Six Sigma Tools
5.Teaching Methods:
Course lecture will be based on the text book and supplemental materialls. Homework will be assigned and collected regularly. Participative exercises and reviews of chapters, assignmnets, and presentatiions will be ongoing.
6.Required Text Books & Materials:
- Introduction to Statistical Quality Control, by D. C. Montgomery, 7th edition, 2009. Wiley, ISBN: 9780470169926.
- Articles or Handouts as appropriate
7.Recommended References:
As posted on canvas.
8.Important Dates
Refer to the UB Academic Calendar for important dates:
First Day for this classThursday, Januarry 19. 2017
Midterm ExamThursday, March 8
No Class,Spring Break/Thursday, March 15
Last Day of Classes, Final Reports dueThurday, April 19
Final ExamThursday, April 26
Final Grades DueMonday, May 8, 2017
9.Course Requirements:
Attendance...... 10%
Homework Submissions...... 20%
Mid-Term Exam...... 25%
Team Projector Individual Research Paper ...... 20%
Final Exam………………………………………………………….25%
Total...... 100%
9.1Attendance 10%
Attendance at each class session is expected. Students must be on time for class. Students must actively participate in class discussion, as required. Each week students will be evaluated accordingly on these dimensions.
9.2Homework20%
Homework demonstrates the regular times spent outside of class to achieve and demonstrate comprehension of assigened material. Any late assignement will be worth half credit.
9.3Mid-term exam25%
A test consistinng of mutiple choice, completion, and problems with solutions will be adminstered for evaluation of comprehension and mastery of topic presented.
9.4Team Project or Individual Research Paper20%
Either participation in a team assignment, or an individual paper if dedication to the field is anticipated, is expected to show use of course content. Individual papers are encouraged only if you plan to go beyond the course material in a signficant manner, as the team experience is part of the learning process.
9.5Final Exam20%
A test consistinng of mutiple choice, completion, and problems with solutions will be adminstered for evaluation of comprehension and mastery of topic presented. While cumulative, the focus will be on the later parts of the course, and any material from the first half not fully masterred.
10.Final Course Grade
Letter Grade / Range (%)A / 94.9 – 100.0
A- / 90 – 94.8
B+ / 87 – 89.9
B / 83 – 86.9
B- / 80 – 82.9
C+ / 77 – 79.9
C / 73 – 76.9
C- / 70 – 72.9
D+ / 67 – 69.9
D / 63 – 66.9
D- / 60 – 62.9
F / Below 60
11.Schedule & Assignments
Week / Date / Time / Topic & Assignments1 / 19-Jan / 6:15 pm –845 p / Overview of Quality Improvement
- Quality Defined
- Dimensions of Quality
- Quality Evolution
- Variation and Statistical Methods
- Quality Management Philosophies
- TQM, Macolm Baldridge, Six Sigma, Quality Standards
- Quality /Productivity and Quality Costs; Product Liability
- Quality Planning, Quality Assurance, Quality Control and Improvement
Assignment: Read Chapter 1, 2
Homework (due in week 2); Assigned in Canvas
2 / 26-Jan / “ / Six Sigma DMAIC Process
- Project Selection
- Define, Measure, Analysze, Improve, Control
- Toll - gate reviews
- When and when not to use DMAI
- DMAIC and Six Sigma Philosophy
Homework (due in week 3) ;Assigned in Canvas
Team or individual project assignments (Define)
3 / 2-Feb / “ / Modeling Process Quality
- Data representation
- Measures of data
- Variables and Probability Distributons
- Discrete and Continuous data
- Probability plots
- Sampling Distribution
- Population Estimates
- Confidence Intervals
- Hypothesis Testing
-ANOVA
-Linear regression
Assignment: Read Chapter 3,4, 5
Homework (due in week 4); Assigned in Canvas
Team or individual project assignments - finalize assignments
4 / 9-Feb / “ / Statistical Process Control
- Chance and Assignable Causes
- Shewhart control chart
- Basic SPC tools
- Control charts for variables, X-bar-R
- Process Capability
- Control chart patterns
- other control charts
- Normality assumption
Assignment: Read Chapters 6, 8
Homework (due in week 5); Assigned in Canvas
Team or individual project assignments - Project Charter
5 / 16-Feb / “ / Process and Measurement Capability
- Control Charts and Capability
- Variation and Specification: Cpk
- Measurement System Analysis
- Normality
Team or individual project assignments - Deliverables
Homework (due in week 6); Assigned in Canvas
6 / 23-Feb / “ / Continuous Process Improvement
- Process Mapping
- Value Stream Mapping
- Brain Storming
- Root Cause Analysis
- 5S
Hands On Class exercise #1 (DMAIC helicopter design)
7 / 2-Mar / “ / Initial project presentations -
Review for mid-term exam;
8 / 9-Mar / “ / Mid-term Exam
9 / 16-Mar / “ / No Class: Spring Break
10 / 23-Mar / “ / Acceptance Sampling
- Role of Acceptance Sampling
- Arrtibutes / Variables, Random Sampling
- Mil std 105E, 414
- Skip-lot and Dock-to-Stock
Assignment: Read Chapters 15, 16
Homework (due in week 11); Assigned in Canvas
11 / 30-Mar / “ / Continuous Process Improvement
- Mistake Proofing
- Poka-Yoke
- Tying it all together
Hands On Class exercise #2 (Assembly processes)
HW: selected readings, see Canvas
12 / 6-Apr / Root Cause Corrective Action Revisited
- G8d, 7step, 5phase = Root Cause Corrective Action USA
- 5 why, A3 Far East
- Applying the quantitative tools
- Cause & Effect for problem solving
HW: selected readings, see Canvas
Hands On Class exercise #2 (RCA - making coffee)
13 / 13-Apr / “ / Quality Planning
- Advanced Quality Planning
- Loss Function / Taguchi DOE
- Review of all quantiative / qualitative quaity tools
HW: selected readings, see Canvas
14 / 20-Apr / “ / Project Presentations - 30 min max -
All written reports due next week
15 / 27-Apr / “ / Project Presentations ; Last day of classes, review for Finals
16 / 04-May / Final Exam
12.General Policies for the Course
12.1Academic Honesty:
- It is the student's responsibility to familiarize himself or herself with and adhere to the standards set forth in the policies on cheating and plagiarism as defined in Chapters 2 and 5 of the Key to UB or the appropriate graduate program handbook.
- If you are caught cheating or plagiarizing, you will be warned once and you will receive a zero (0) grade for that assignment. A second offense will result in an F grade for the course.
12.2Attendance:
- For on-campus classes, the fourth unexcused absense will result in a failure of the class.
- All abscences must be explained, with suitable effort to make up missed material
12.3Work Effort:
- As a UB policy, for a three credit course, it is expected that each student that attends one hour of classroom instruction will require a minimum of two hours of out of class student work each week for approximately fifteen weeks for one semester in compliance with the Carnegie Unit of Credit.
12.4Assignment Content Expectations and Evaluation:
- Homework assignments and programs are due within a week from the assignment date, unless the instructor notes otherwise.
- All homework assignments are to be typed, scanned, and emailed when due.
*pdf preferred, or any MS Office file format - Extra credit quizzes, assignments, and programs (if any) will be announced by the instructor.
- The following rubric will be used for evalutation of written submissions:
Grade Criteria / A Exemplary / B Adequate / C Poor
Content / The content was clear and useful. The writer gave specific answers relevant to the topic. / The content was generally relevant, but was somewhat unclear or confusing at times. / It was unclear as to how the content related to the field being considered.
Critical Analysis / The writer was thought provoking and showed strong insight in applying class materials to the cased or topic. / The writer was able to reflect on the topic. A Thoughtful assessment was included. / The writer did little more than restate facts and other people’s (authors’) opinions.
Spelling and Grammar / Spelling and grammar rules were followed. Technical writing rules were followed. / Although most of the paper was well written, a more than a few grammar, spelling, and/or technical errors were present. / The paper was poorly written – making it difficult to determine the writers points. Numerous grammatical and spelling errors were present. The text did not follow rules for technical writing.
Overall Quality / The paper meets the requirements for the degree program for student is enrolled / The paper lacks one or a few elements that are important for the program / The paper was poorly written.
12.5Deadlines and Late Policy:
- Assignments must be submitted by the deadline to receive any credit.
- Late homework / project assignment submission will not be accepted, or penalized
- Late homework will only be considered for half credit.
- Make-up exams / quizzes will not be allowed (except for prior instructor approval for a documented emergency)
12.6Personal Devices:
- The use of portable devices is prohibited. Students must turn off and stow all personal devices (phones, tablets, etc.) during class.
- Laptops may be used in class.. No internet acces - unless class exercise indicates use warranted.
12.7Special Student Situations:
- Veterans and student service members with special circumstances or who are activated are encouraged to notify the instructor as soon as possible and to provide Activation Orders.
- Any students with disabilities or other special needs requiring special accommodations in this course should work with the Office of Disability Services. The Professor will cooperate with the Office of Disability Services to provide appropriate accommodations for the student. For additional details, refer to The Key to UB, “Disability Service.”
Appendixes
A1.Term paper Details
Individual research papers can be based on text book chapters not covered, or research on a topic presented in class. Only individuals who anticipate future research or appllication in this area are encourage, as a team project is more suited to the workplacne and team-based learning and deployment. A paper would be three or more pages, with many references cited to show comprehesion and appllication of the topc
A2.Team project Details
Most class participants are encoouraged to participate in a team project, which will require a group in-cleas presenation and a group written report, with individual commenteary.
A3.Additional Resources
Jurans’s Quality Control Handbook.