1 smu emis 7364 ntu to-570-n basic concepts updated 1.14.04 statistical quality control dr. jerrell...
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SMUEMIS 7364
NTUTO-570-N
Basic Conceptsupdated 1.14.04
Statistical Quality ControlDr. Jerrell T. Stracener, SAE Fellow
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Statistical Quality Control - Basic Concepts
• Introduction and basic concepts
• Statistical analysis of process capability
• Statistical process control
• Process design and improvement
• Sampling
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Statistical Quality Control - Basic Concepts
I will explain the role of quality throughout theproduct life cycle (engineering and design, manufacturing/production and support) to:
increase the relevance of techniques and methods
increase your ability to apply techniques and methods
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Statistical Quality Control - Basic Concepts
The concepts, techniques and methods are coveredin this course are applicable (with tailoring)
to all products: hardware, software, service
over the product life cycle
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Statistical Quality Control - Basic Concepts
• What is quality?
• What are the features of quality?
• How is quality measured?
• How do we know the level of quality?
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Statistical Quality Control - Basic Concepts
This course is statistical quality control
It is not a statistics course
It is an application of statistical techniques toquality control
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Statistical Quality Control - Basic Concepts
Introduction and basic concepts
Fundamental concepts of qualityDimensions of qualityQuality metricsTotal quality managementBasic concepts of statistical quality controlQuality improvement toolsSix Sigma concepts
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Statistical Quality Control - Basic Concepts
Analysisof processcapability
Statisticalprocesscontrol
Processimprovement
Acceptancesampling
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Statistical Quality Control - Basic Concepts
• Quality begins with customer requirements
• Quality must be designed in. It cannot be inspected in!
• Quality depends on:
Parts selection and procurementMaterialManufacturing/production processesLogistic processes
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Statistical Quality Control - Basic Concepts
• 19901. Reliability2. Durability3. Easy maintenance4. Ease of use5. A known or trusted brand name6. Low price
• 19851. A well known brand name2. Workmanship3. Low price
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Statistical Quality Control - Basic Concepts
• The glow and tingle factorWhich makes a customer choose one productover another when their quality is equal
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Dimensions of Quality
• Performance - Will it do the intended job?• Reliability - How often does it fail?• Durability - How long does the product last?• Serviceability - How easy is it to repair the product?• Aesthetics - What does the product look like?• Features - What does the product do?• Perceived Quality - What is the reputation of thecompany or its product?• Conformance to Standards - Is the product madeexactly as the designer intended?
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The Level of Quality
The Goodness Level of 99% Equates to:• 20,000 lost articles of mail per hour• Unsafe drinking water almost 15 minutes per day• 5000 incorrect surgical operations per week• 2 short of long landings at most major airportsper day• 200,000 wrong drug prescriptions each year• No electricity for almost 7 hours per month
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Statistical Quality Control - What is quality?
• Quality is meeting the customer’s needs over thelife cycle of the product at the best value to the customer
• Quality has many dimensions
ReliabilityMaintainabilityPerformanceDurabilityConformance (to requirements and expectations)
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Obstacles to Quality Improvement
• Making it happen- 99% agree that management is the problemnot the workers- 35% of the problem is ‘not invented here’ syndrome
getting their attention and educationresistance to change
- 15% gaining management commitment- 14% communication
getting the word out within the company
• Failure of management to understand ‘variation’
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How TQM Works
• Builds and sustains a culture committed to continuous improvement• Focuses on satisfying service needs and expectations• Requires dedication, commitment, and participationfrom top DoD leadership• Involves every individual in improving his/her ownprocesses• Creates teamwork and constructive working relationships• Recognizes people as the most important resource• Employs the best available management practices,and tools
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TQM Principles
• Continuous process improvement- Implemented through a structured anddisciplined approval- Emphasis is placed on preventing defects
• Process knowledge- Change is created by those who understandthe process
• User focus- Understand the needs of all users
• Commitment- Requires commitment at all levels, startingat the top
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True Impact of Product Variability
• Loss function - dollar loss due to deviation of product from ‘ideal’ characteristic
- dimension- surface finish- elasticity- gain- other
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True Impact of Product Variability
• Sources of loss- scrap- rework- warranty obligations- decline of reputation- forfeiture of market share
• Loss characteristic is continuous - not a step function
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Key Elements of VRP
• Sources of loss- scrap- rework- warranty obligations- decline of reputation- forfeiture of market share
• Loss characteristic is continuous - not a step function
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