QUAL08001 2013 Statistical Process Control

General Details

Full Title

Statistical Process Control

Transcript Title

Statistical Process Control

Code

QUAL08001

Attendance

N/A %

Subject Area

QUAL - Quality Control

Department

MENG - Mech. and Electronic Eng.

Level

08 - NFQ Level 8

Credit

05 - 05 Credits

Duration

Semester

Fee

€

Start Term

2013 - Full Academic Year 2013-14

End Term

2019 - Full Academic Year 2019-20

Author(s)

JOHN DONOVAN

Programme Membership

SG_EQLTY_K08 201300 Bachelor of Science (Honours) in Quality Management and Tech SG_EADVA_E08 201500 Level 8 Certificate in Advanced Lean Sigma Quality SG_ELEAN_E08 201300 Level 8 Certificate in Engineering in Lean Sigma Quality SG_ELEAN_E08 201400 Level 8 Certificate in Engineering in Lean Sigma Quality SG_EPOLY_K08 201800 Bachelor of Engineering (Honours) in Engineering in Polymer Processing

Description

Provides the student with a comprehensive understanding and knowledge of the use of statistical methods and techniques for monitoring and controlling processes.

Learning Outcomes

On completion of this module the learner will/should be able to;

Use and apply the basic problem solving techniques of quality to analyse data.

Apply qualitative tools for problems solving, prioritising problems and improving processes.

Develop, plot and analyse both variable and attribute Shewhart control charts.

Construct and use a EWMA chart

Apply short run and standardised control charts.

Conduct process and gauge capability analysis and develop the capability indices.

Conduct acceptance sampling by attribute and by variable data using ANSI/ASQC Z1.4 and ANSI/ASQC Z1.9 respectively.

Apply skip-lot, continuous and chain sampling procedures.

Teaching and Learning Strategies

Real world examples, case studies and published peer reviewed papers will be utilised, where possible.

Module Assessment Strategies

Students will be required to complete three assignments.

Module Dependencies

Prerequisites

MATH08005 201300 Statistics

Indicative Syllabus

Review of Quantitative Tools - Incl. The Seven Tools of Quality: (5%)

Histograms: How to prepare and use a Histogram. Mean, Mode, Median. Meaning of variation.

Cause and Effect Diagrams : Making CE diagrams. How to use CE diagrams.

Check Sheets: Function of check sheets. Types and uses of check sheets.

Graphs : Types of graphs. How to make and use graphs.

Pareto Analysis : How to make and use a Pareto diagram. Inclusion of cost on y-axis.

Scatter Diagrams:How to make and use a scatter diagram. The meaning of correlation

Boxplots : How to make and use boxplots. Comparing batches of data using boxplots.

Stem-and-Leaf Displays :How to make and use stem-and-leaf displays to see patterns in data.

Review of Qualitative Tools: (5%)

Brainstorming and Nominal Group Technique.

Affinity diagram - gathering and grouping ideas

Interrelationship Diagrams - looking for drivers and outcomes

Radar Chart - rating organisation performance

Force Field Analysis - positives and negatives of change

Tree Diagram - Mapping the tasks for implementation

Prioritisation matrices - weighing options

Control charts: (35%)

Review of Common cause and Special cause variation and and R variable control chart. Attribute control charts i.e. p, np, c and u charts. Individual X and Moving Range charts. Average Run Length, Short Run SPC, Standardised Run Charts. EWMA charts. SPC for Low Defect Environments

Process Capability (25%)

Review of of and . How to calculate capability indices using both the and R method. and indices. Gauge capability studies. The components of measurement error - repeatability and reproducibility. Precision-to-Tolerance ratio. Use of control charts in determining gauge capability. Tolerance limits for interacting dimensions.

Acceptance Sampling (15%)

Principles of Acceptance sampling. Single sampling plans and their associated OC curves. Use of statistical tables to develop both the sampling plan and the OC curve.

Lot formation considerations. Single, and double sampling plans. Calculation of Average Sample Numbers (ASN). Average Outgoing Quality.

Sampling Standards: (15%)

Detailed focus on ANSI/ASQC Z1.4 (Acceptance Sampling by Attributes). Calculation of Average Fraction Inspected (AFI). Acceptance sampling by Variables - detailed focus on ANSI/ASQC Z1.9. Skip Lot sampling. Continuous Sampling plans. Chain Sampling.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment

20 %

End of Semester / Year Formal Exam

80 %

Coursework Assessment

	Title	Type	Form	Percent	Week	Learning Outcomes Assessed
1	Assignment . Three assessments	Coursework Assessment	UNKNOWN	20 %	OnGoing	1,2,3,4,5,6,7

End of Semester / Year Assessment

	Title	Type	Form	Percent	Week	Learning Outcomes Assessed
1	Final Exam One written 2.5 hour paper	Final Exam	UNKNOWN	80 %	End of Term	1,2,3,4,5,6,7,8

Full Time Mode Workload

Type	Location	Description	Hours	Frequency	Avg Workload
Lecture	Not Specified	Lecture	2	Weekly	2.00
Tutorial	Not Specified	Tutorial	2	Weekly	2.00
Independent Learning	UNKNOWN	Independent Learning	4	Weekly	4.00

Total Full Time Average Weekly Learner Contact Time 4.00 Hours

Part Time Mode Workload

Type	Location	Description	Hours	Frequency	Avg Workload
Lecture	Not Specified	Lecture	2	Weekly	2.00
Tutorial	Not Specified	Tutorial	2	Weekly	2.00
Independent Learning	UNKNOWN	Independent Learning	4	Weekly	4.00

Total Part Time Average Weekly Learner Contact Time 4.00 Hours

Module Resources

Non ISBN Literary Resources

Authors	Title	Publishers	Year
Montgomery, Douglas	Statistical Quality Control: A Modern Introduction	John Wiley & Sons	2013
Oakland, John	Statistical Process Control	Butterworth-Heinemann Ltd	2007
Ryan, T.P.	Statistical Methods for Quality Improvement	John Wiley & Sons	2011
Henderson, Robin	Six Sigma Quality Improvement with Minitab	John Wiley & Sons	2011
Wheeler, Donald	Andavced Topics in Statistical Process Control	SPC Press	2004

Other Resources

None

Additional Information

None