# 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
9999 - The End of Time
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_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;

1.

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

2.

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

3.

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

4.

Construct and use a EWMA chart

5.

Apply short run and standardised control charts.

6.

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

7.

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

8.

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 Continuous 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

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

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