TCMG 524 – Statistical Process ControlFall 2016

University of Bridgeport School of Engineering

Technology Management Program

TCMG 524

Statistical Quality Control

Fall 2016 Semester (8/29/16 – 12/12)

Tuesday, 6:15-8:45

Course Syllabus

Room: Mandeville TBD

Instructor: Dan Tenney

MBA, CQE, LSS Coach

Office Location: Tech Building, Room 211 or Library

Office Hours: 5:30pm Monday or other (by email appointment)

Course Overview

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, but not limited to 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, how these methods are applied and what the eventual outcome of usage may be.

Statistical quality control and improvement is more than an engineering concern. Quality has become a major business strategy for increasing productivity and gaining competitive advantage. This course presents a comprehensive summary of methods for managing quality through the use of statistical methods, continuous improvement methodologies and what the expected outcome of usage will be. Quality Control without Quality Management is ineffective. We will explore the meaning behind and how these tools can be most effectively used.

The teaching approach consists of lectures, practical case studies and examples, team problem solving, class readings/homework assignments, use of current events relating to Statistical Quality Control, and an individual research term paper.

Course Learning Objectives

The course objective is to develop an operational familiarity with Statistical Quality Control, and the basis for applying them in a variety of situations. Continuous process improvement methodologies and techniques will be covered and applied to real life applications.

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.

Course Topics

Course topics include:

  • Introduction to basic concepts of quality improvement , management and quality control
  • An overview of Statistical Quality Control methods
  • Six-Sigma Process and the DMAIC Roadmap( and requisite tool usage)
  • Practical Industry Quality examples and outcomes
  • Root cause problem identification, analyses and resolution
  • Statistical Process Control and Capability Analyses (Control Charting, Capability, etc.)

Text Books and Readings

  1. Introduction to Statistical Quality Control, by D. C. Montgomery, 7th edition, 2009. Wiley, ISBN: 9780470169926.
  2. Articles:
  3. Handouts as appropriate
  4. Additional readings may be added as appropriate throughout the course

The text or relative chapter of the electronic text, and any handouts must be brought to every class.

Software

General spreadsheet presentation software – preferably Microsoft will be used periodically throughout the course.

Course Requirements

  1. Class Attendance, Participation, Punctuality, Cheating and Plagiarism:

Timely attendance at each class session is expected. Class lectures complement, but do not duplicate, textbook information. Together students and instructor will create a learning organization. Students are expected to be on-time for class. A significant portion of your learning will accrue through the constructive and respectful exchange of each other’s ideas and search for alternative solutions. You must be actively engaged in class discussions to improve your thinking and communication skills.

Cheating and plagiarism is absolutely unacceptable in any guise. Cheating and plagiarizing means using the work of others as your own. Copying homework, using papers from the Internet, any talking or looking around during exams and allowing others to look at your exam papers are examples of cheating.

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 by UB policy in the appropriate on-line and program guidelines..

More than 2 unexecused absenses will result in class failure.

  1. Preparation, Deadlines and Late Policy:

Late assignments will be penalized 20% for each class day past the deadline. No excuses will be accepted without teacher consent. Don’t wait until the last minute to print out your assignment.

  1. Homework:

The syllabus identifies both the homework assignments. Each assignment should be typed and only one or two pages long. It will be collected per the schedule and may be referred to during class discussion.

  1. Term Team Project and Presentation*:

By the second class session, teams will be formed. Each team will be responsible for developing a final course project. At the end of the course, the team will present to the class and give a hardcopy of the PowerPoint presentation to the instructor when the students are scheduled to make the presentation.

To receive a high grade, every member of the group must equally participate in the presentation, its preparation and delivery.

*Discussed in first class. Use of DMAIC Six Sigma problem solving, Statistical

Quality control tools will be required.

Suggested topics for a Team project include:

  • Case studies in Six Sigma application
  • Case studies /literature review in Quality leadership and how to apply appropriate tools
  • Lean Management and it’s applicable tools relative to SQC .
  • Case Studies in Quality Improvement
  • The Importance of ASQ Certifications – Why, What, How and So What
  • Cost of Quality – Why, What and How?
  • Other Topics are acceptable with the approval of the instructor
  1. Individual Written Final Term Summary Paper:

Each student will prepare a written term paper (1-2 pages, double space, 12 point font). All papers must summarize your experience, what you found to be the most effective learning tools and references.

  1. Course Grading

Assignments

Class(homework,participation)25%

Mid-term Exam40%

Team Project25%

Individual Term Summary Paper10%

100(Bonus pts at instructor discretion)

One or more quizzes may be given at the discretion of the instructor.

Attendance / participation will be considered as a part of the final exam grade.

Bonus points may be credited throughout the course.

The grading is subject to change and the changes will be communicated with the students.

Canvas will be used for assignment, grading and course information.

All papers must meet anti-plagarism requirements as defined by the university and accepted standards.

  1. Course Structure

Lecturing is only one of the three approaches used in this course. Knowledge will be acquired through facilitated class discussion and student presentations. Students are expected to engage actively in preparing for and participating in course discussions. For completing the assignment and project, students may need to do additional research, and look for information and knowledge that is not covered by the textbook and the lectures. It is assumed that a major learning objective for this course is to cultivate students’ capability in searching, identifying, evaluation, using, and integrating relevant knowledge that may or may not be provided in the class.

Schedule is subject to change based on pace/student background/topic interest

Important Dates:

Classes Begin: 8/29 Monday

Mid Term 10/24 Monday (or when through base curriculum)

Last Day of Class:12/5 Monday

Schedule & Assignments

Date / Topics and Assignments / Reading (must be done before class)
Sessions #1 #2
8/29/9/12 / Overview of Statistical Process Control
Importance of Statistics and Process Control
Terminology
History
Quality Philosophy and Management Strategy
Deming, Juran
Quality Standards
Baldrige Award
Six Sigma
Lean
Formation of Project Teams(week 2)
Homework (Due in week 2)
Assigned in Canvas / Read:
- Chapter 1 (All)
Session #3
9/19 / DMAIC Process
Homework ( Due in Week 3)
Assigned in Canvas / Read:
- Chapter 2 (All)
Session
#4 & #5
9/26/10/3 / Modeling Process Quality
Statistical Methods
Median, Mean, SampleRange,
Standard Deviation
Sample Variance
ProcessCapability
Stem and Leaf Plot
Histogram
Box Plot
Hypothesis Testing
  • Z-Scores
  • Correlation & Regression Analysis
  • ANOVA
Homework (Due in week 4)
Assigned in Canvas / Read:
- Chapter 3 (All)
- Chapter 4 Pages 112-120; 150 – 157)
Team proposal due by 2/24
Session #6& #7
10/10, 10/17 / Midterm 3/17
Statistical Process Control
Control Chart
X Bar R Charts
P and NP Charts
C Charts
Check Sheet
Pareto Chart
Scatter Diagram
Defect Concentration Diagram
Cause and Effect Diagram
Homework (Due in week 5)
Assigned in Canvas / Read:
- Chapter 5,6,8 (all)
Preparation for midterm exam
Sessions #8
10/24 / Continuous Process Improvement
Lean/DMAIC/other tools
Process Mapping
Value Stream Mapping
Brain Storming
Root Cause Analysis
5S / Selected class presentation and participation
Session 10
10/31 / Continuous Process Improvement
Mistake Proofing
Poka-Yoke
Tying it all together / Selected class presentation and class participation
Sessions #9 and 1011/7/11/14 / Acceptance Sampling
  • Acceptance sampling problems
  • Advantages, disadvantages
  • Lot formation
  • Types of plan
Hands on team exercise in using the tools of Continuous Improvement,
Possible guest lecturer or field trip / Read Chapters 15,16
Cases will be discussed in class. Recap of tool usage and lagging questions.
Sessions #11 and 12 11/21/11/28 / •Due : Final Team Project
•Make a 20-30 minute presentation of your team course project to the class. Use visuals. Submit a copy of the presentation visuals.
Possible guest lecturer or field trip / Teams will present their team projects
Session #15
12/5 / Last day of classes/ recap 4/28
Review of topics, questions and answers, and submit final summary paper. May substitute a field trip, and/or guest lecturer in any one or two sessions / Individual paper submittal and recap discussion

1