Quality (PTAC 2314)

Instructor

Instructor

Prof. Prateek ‘Pat’ Tripathi, MS (Industrial Engineering)

Contact Info

[email protected]

Course Description and Objectives

Pre-requisites

TBD

Type of Instruction

This is an on-campus courses, and is delivered in person. Methods of instruction will include but are not limited to face to face lecture, discussions, textbook and required readings if chosen by instructor.

Description

Introduction to modern Quality control tools and techniques to improve the product’s quality and the manufacturing process by identifying assignable causes of variation.

The laboratory component provides “hands-on” practice with modern metrology equipment and techniques as well as Data analysis and Statistical control charts interpretation. 

Learning Objectives

SLO #1 Explain the definition of Quality, Quality control, and Statistical process control.

1.     List the seven tools of SPC

2.     Recognize the difference between error prevention and error detection

3.     List SPC tools

SLO #2 Explain the role of Management/Employees in Quality Assurance.

1.     Define Total Quality Management

2.     Define Quality from the customer’s perspective

3.     Define ISO 9000 and its role in the global Quality

SLO #3 Understand the concept of variability management and its role in Quality Assurance.

1.     Describe types of variability

2.     List basic statistical concepts

3.     Calculate mean, median, mode, range, and standard deviation for a set of numbers

SLO #4 Organize the collected data and create charts

1.     Define a Pareto chart

2.     Explain a Histogram purpose

3.     Draw a flowchart

4.     Make a Cause and effect Diagram

SLO #5 Use probability and historical Data to forecast production output.

1.     Define probability and distribution

2.     Define combinations and permutations

SLO #6 Make a  and R chart to identify process variations.

1.     Interpret x-bar and R charts to define the variable quality characteristics

2.     Develop, analyze, and interpret p-chart and C charts to analyze the quality attributes

3.     Understand and determine control limits

SLO#7 Calculate and Interpret process capability  

Interpret process capability indexes to compare process tolerance with design tolerance

4.     Compute and interpret Cp and Cpk

5.     Analyze and interpret Gauge R&R (repeatability and reproducibility)

SLO#8 Explain lean six sigma quality management practices

1.     Explain what the DMAIC six sigma tool is

2.     Make and interpret a process Value stream mapping

3.     Explain the 5S, Kaizen, and Poke-yoke Lean Tools

4.     List the seven basics tools of quality

SLO #9 Explain the Problem Solving techniques

1.     Define what a structured approach to problem solving is

2.     List the Problem solving sequence

Textbook and Materials

1.     Smith, G.M., 2004; Statistical Process Control and Quality Improvement, Fifth Edition, Prentice Hall, New Jersey.

2.     Lecture notes by instrructor

Course Outline

Week

Topic

Chapter

Lab Modules

1

Introduction to Quality and SPC, Total Quality Management, ISO 9000

1 & 2

2

Measurements Concepts , Types of variability

Basic Statistical Concepts

3

3

Data Collection and Organization

Distributions and Standard Deviations

3

4

Control Charts, Histogram, Histogram Analysis

Pareto Charts

4

5

Flow Charts, Process Mapping, Cause-and-Effect Diagram

4

6

Introduction to probability, Compound probability

Factorials

5

9

Variables and Attributes

The  and R Procedure

6

10

Process capability, Variables and Attributes

Control Charts for attribute data

6

11

Problem Solving, The problem-solving Sequence

6

12

12

Gauge Capability

Gage R&R

11

13

Lean Manufacturing Principles

Lean Tools

Introduction to Six-Sigma

Six Sigma Tools

12

14

Final Exam

6

Lean Handout

Six Sigma Handout

Grading Policy

HCC Grading Scale

LETTER GRADE / NUMERICAL GRADE

         A                              90-100      Excellent

         B                              80-89        Good

         C                              70-79        Fair

         D                              60-69        Passing

         F                               59-0          Failing

Grade Breakdown

Instructor’s discretion

(Attendance, attitude,

Class participation, etc.):                  10%

Assignments and Projects:               50%

Final Exam:                                         40%

                                                             100%

Lab Module Outline

Lab 1

Quality terms Web Search: After the lecture of the first-class meeting, have the students answer the questions on Attachment 1.

Objective: To memorize fundamental terminology and concepts which are the Foundation for the following subjects.

Lab 2

Have the students use just a tape measure to record 4 critical dimensions for the ten provided parts.

Note to the Instructor: Please request 10 Step block parts from the Basic Mill teacher.

Objective: Students should notice variation on the measurements due to different variables: the measuring tapes used, different students taking dimensions, different parts.

The importance of using precision metrology instruments should be brought up.

See Attachment 2 Step Block

Lab 3

Using this time a dial caliper and a height gauge have the students take the same dimensions from the previous week.

Have the students use a Micrometer to measure and record the 5 diameters from the Step Shaft.

Objective: Stress the importance of using accurate instrumentation. Point out the human intervention on manual instruments. 

See Attachment 3 Step Shaft

Lab 4

Using the table created the previous week, find the Standard Deviation for each of the dimensions taken. Use the nominal dimension or Target dimension as the .

Analyze the data and see how disperse and far from the target is.

Objective: Students to understand the use and purpose of Data Organization and how to calculate the SD. Use MS Excel for the calculations.

See Attachment 3 and Excel file Standard Deviation

Lab 5

1-Using the tables from previous week, have the students calculate the  and  for the Data of the whole class. Create a Control Chart.

Objective: Students to interpret and understand the purpose of a Control Chart.

See Excel file Control Chart

Lab 6

 Using the exercise provided on Excel File 2, create a Control Chart with plus and minus three times the SD for a confidence of 99.7%.

Lab 7

Solve exercises on page 124 of the text book.

Lab 8

Create a Chart using the attached Excel File Pareto Exercise 1 

Objective: understand the purpose of a Pareto chart

Lab9

Solve exercises on page 184 of the text book.

Lab 10

Have the students draw a Flowchart for the exercises on Flowchart handout.

Objective: Students to make a graphical representation of a process.

Lab 11

Solve exercises on page 255 of the text book.

Lab 12

After providing the Handouts about Lean and Six Sigma methodologies, have the students follow the link on the Six Sigma case study file, watch the video and answer the questions.

COURSE POLICIES

Attendance

Students are expected to attend classes regularly, and to be on time for every class period. Students can be dropped from a class due to excessive absences. Excessive tardiness may be considered absences. Students are responsible for subjects, assignments, and projects covered during their absences. Consult the Student Handbook for more details or visit http://www.hccs.edu/district/students/student-handbook/

Academic Honesty

Scholastic dishonesty is treated with the utmost seriousness by the instructor and the College. Academic dishonesty includes, but it is not limited to the willful attempt to misrepresent one’s work, cheat, plagiarize, or impede other students’ scholastic progress.  Consult the Student Handbook for more details.

Student with Disabilities

Any students with a documented disability who needs to arrange reasonable accommodations must contact the Disability Services office at the respective college at the beginning of each semester. Faculty is authorized to provide only the accommodations requested by this office. For questions, contact Donna Price at 713-718-5165. To visit the ADA web site, log on to www.hccs.edu, click Future Students, scroll down the page and click on the words Disability Information.

Cell Phones

All cell phones must be muted, set to vibrate, or turned off during class

Calculators

If the course allows the use of a calculator during class, lab projects, and exams, the student is responsible to bring his/her calculator.

Student ID

Students are required to obtain a Student ID. For additional information, consult the Student Handbook.

Parking Rules and Regulations

Students are required to follow HCC’s regulations regarding parking and permits. For additional information, visit http://www.hccs.edu/district/departments/police/hcc-police-services/parking-rules-and-regulations/

Books, Tools and Supplies

Students are required to purchase and bring to class the required textbooks, tools, notebooks, supplies, and writing instruments as required by the instructor.

Dress Code

Dress code must be appropriate for the class. Students must dress in a way that clothing and accessories do not compromise their safety, and the safety of others. Proper foot wear is required in all laboratories.  Absolutely no sandals or other footwear that exposes the feet will be allowed.

Classroom & Laboratory Conduct

Proper behavior is expected in all classes and laboratories. Foul language and horseplay are not allowed. Making or receiving cell phone calls during class are not allowed. Sleeping in class is not allowed.

Course Withdrawal

It is the responsibility of the student to officially withdraw from a course before the official withdrawal deadline. A student who does not withdraw from a course by the deadline will receive an “F” as the final grade. Also note that under Section 51.907 of the Texas Education Code, an institution of higher education may not allow a student to drop more than six courses.

Complaints

HCC is committed to provide learning and working environment that is free from discrimination on the basis of sex which includes all forms of sexual misconduct. Title IX of the Education Amendments of 1972 requires that when a complaint is filed, a prompt and thorough investigation is initiated. Complaints may be filed with the HCC Title IX Coordinator available at 713 718-8271 or email at [email protected].

Access Student   Services Policies on their Web site

http://www.hccs.edu/district/about-us/policies/d-student-services/

Distance Education Policies

Access DE Policies on their Web site:  

All students are responsible for reading and understanding the DE Student Handbook, which contains policies, information about conduct, and other important information. For the DE Student Handbook click on the link below or go to the DE page on the HCC website.

The Distance Education Student Handbook contains policies and procedures unique to the DE student. Students should have reviewed the handbook as part of the mandatory orientation. It is the student's responsibility to be familiar with the handbook's contents. The handbook contains valuable information, answers, and resources, such as DE contacts, policies and procedures (how to drop, attendance requirements, etc.), student services (ADA, financial aid, degree planning, etc.), course information, testing procedures, technical support, and academic calendars. Refer to the DE Student Handbook by visiting this link:

http://de.hccs.edu/media/houston-community-college/distance-education/student-services/pdf/2015-HCC-DE-Student-Handbook-(Revised-5_28_15)_will.pdf

EGLS₃ (Evaluation for Greater Learning Student Survey System)

At Houston Community College, professors believe that thoughtful student feedback is necessary to improve teaching and learning. During a designated time near the end of the term, you will be asked to answer a short online survey of research-based questions related to instruction. The anonymous results of the survey will be made available to your professors and department chars for continual improvement of instruction. Go to http://www.hccs.edu/district/students/egls3/  for more information.

Teacher/Student Responsibilities

Instructor

·       Provide the grading scale and detailed grading formula

·       Facilitate an effective learning environment

·       Provide the course outline and class calendar

·       Arrange to meet with individual students as required

·       Inform students of course policies

·       Be available to answer questions or concerns regarding the course materials

Student

·       Attend class and participate in class discussions forums and activities

·       Keep up with assigned readings

·       Complete the required assignments and assessments

·       Ask for help when there is a question or problem

·       Keep copies of all paperwork, including this syllabus