The traditional role of quality control is basically to elimaincate from production lines those parts that do not conform to specifications, and to inspect and testfinish products for defects. Given this definition, quality control is almost limited to inspecting and testing on a detailing or samling basis.

 The increased emphasis on :higher quality" products at lower costs, combined with the competition from overseas for U.Su. markets, has magnified the importance of quality control. Consequently, quality control activities have been redefined to ensure the quality of the product during every phase of its life cycle. This book describes quality control from an engineering standpoint. It is intended to amplify the concept of :on-line: quality control as applied during production.

 Chapter 1 provides a comprehensive discuttion on the value of product quality and the relationship between product quality and price. The chapter also introduces the conceptr of an Overall Quality Control System, including its components and applications.

 Chapter 2 covers a "loss fuction" approach as a measure of quality, and tis use in determining product specification, target values of product characteristics, and desired tolerance(s) relevant to each target value.

 The aim of chapter 3 is to discuss tolerance design as well tolerancing for each of three basic types of variable characteristics.

 Chapter 4 presents "on-line process parameter control: for variable characteristics are ecamined in Chpter 5.

 Chapter 6 provides approcaches for an on-linequality control system for attribute characteristics, including techniques for determining the optimal diagnosis interval and its effect on the quality loss per unit of production.

 Chapter 7 considers different methods for improving the parameters of the production, diagnosis, and adjustment processes to minimize the total quality loss. 

 Chapter 8 discusses the use of preventive maintenance as a means of improving the parameters of the production process to reduce the quality loss of production.

 Examples are provided throughout this book to reinforce and illustrate the concepts, methods, and approaches involved. The end of each chapter contains problems to facilitate practice.

 This book is intended primarily for those involved in the research, development, and manufacturing phases of a product's life-cycle, including design engineers, production and manufacturing engineers, quality engineers, and applied statisticians. It is also intended for senior undergraduate students and first year graduate students in industrial-, production-, manufacturing-, and systems- engineering disciplines. Students should have a familiarity with basic statistical quality control.

 Although we have included a few results of our own research, this textbook is not soley the work of the three authors, and the many refernces throughout the book relfect our indebtedness to others. We have attempted to give appripriate credit to everyone involved. We would like particularly to acknowledge the Japanese Standards Assiciation for permission to use certain material in Chpters 6 and 7.

 The interset in this book was originated by Thomas Hsiang when he worked for Bell Communications Research, Inc. (Bellcore) as the District Manager Qualith and Reliability Engineering at the Quality Assurance Operations Center. During his tenure, Genichi Taguchi and Elsayed A. Elsayed served as consultants to the Qualith Assureance Operations Center. We are grateful to Bellcore for the continued editorial, technical, typing, and drafting support. In paricualr, we wish to express our thanks to Pete Pence and Norm Sherer for their support during the initiaion of this work; Jen Tang for his technical review; Loinel Howard, Jr., and Jim Falk for their assistence and coordination in making the publication of this book possible; Donald Rector and Pamela Richardson for their editorial work and Christine DeHanes for her managerial efforts in the professional typing, editing, formatting, and drafting of this work.

Preface  xiii

1 Quality Value and Engineering  1

 1.1 An overall Quality System  2

 1.2 Quality Engineering in Product Design  5

  1.2.1 System Design  5

  1.2.2 Parameter Design  5

  1.2.3 Tolerance Design  7

 1.3 Quality Engineering in Design of Production Processes  7

  1.3.1 System Design  7

  1.3.2 Parameter Design  7

  1.3.3 Tolerance Design  8

 1.4 Quality Engineering in Production  8

 1.5 Quality Engineering in Customer Service  9

 1.6 Summary  9

     Problems  9

     References  10

2. Loss Function and Quality Level  11

 2.1 The Loss Function  12

  2.1.1 Derivation of the Loss Function13

  2.1.2 Uses of the Loss Function  15

  2.1.3 Economic Consequences of Tightening Tolerances as a Means to Improve Quality  17

  2.1.4 The Loss Function for Similar Products (or for a System with Independent Components)  18

  2.1.5 The Loss Function and Justification of Improvements  19

  2.1.6 The Loss Function and Inspection  20

 2.2 Quality Evaluaions and Types of Tolerances  24

  2.2.1 The-Nominal-The-Best (N Type)  25

  2.2.2 N-Type Tolerance When the Plus and Minus Tolerances Are of Equal Amount  25

  2.2.3 N-Type Tolerance When the Plus and Minus Tolerances Are Not Equal  30

  2.2.4 The-Smaller-The-Better (S Type)  33

  2.2.5 The-Larger-The-Better (L Type)  34

 2.3 Determinations of Tolernances  37

 2.4 Summary  39

     Problems  39

     Refernaces  44

3 Tolernce Design and Tolerancing  45

 3.1 Funciotnal Limets and the Sicietal Loss  46

 3.2 Tolerance Design for The-Nominal_The-Best (N Type)  48

 3.3 Tolerance Design for The-Larger-The-Better Characteristics (L Type)  50

 3.4 Tolerance Design for The-Smaller-The-Better Characteristics (S Type)  51

 3.5 Tolerance Allocation for Multiple Components  54

 3.6 Nonlinear Tolerancing  58

 3.7 Summary  59

     Problems  59

     References  63

4 On-Lines Feedback Quality control: Variable characteristics  64

 4.1 Feedback Control with Measurement Interval of One Unit of Production  65

  4.1.1 Mean Squared Drift  65

 4.2 The Loss Function  68

 4.3 Feedback Control with Measurement Intercals Greater than One Unit of Production  68

  4.3.1 Control System for Lot or Batch Types of Production  73

 4.4 Summary  77

     Promblems  77

     References  81

5 On-Line Process Parameter Control: Variable Characteristics  82

 5.1 Process Parameter Tloerance  83

 5.2 Process Parameter Feedback Control Systems  84

 5.3 Measurement (Prediction) Error and Process Control Parameters  90

 5.4 Summary  95

     Problems  96

     References  99

6 On-Line Quality Control: Attribute Characteristics  100

 6.1 Checking Interval for Attribute Characteristics 101

  6.1.1 Optimal Interval between Successive Diagnoses  105

  6.1.2 Optimal Interval between Successiver Diagnoses for Processes with Small Numbers of Defects  109

  6.1.3 Sensitivity Analysis and Process Recovery  112

 6.2 Frequency of Process Diagnosis  116

 6.3 Summary  119

     Promblems  119

     References  121

7 On-Line Quality Control: Methods for Procss Improvements  123

 7.1 Production Process Improvement Methods  123

  7.1.1 Preventive Tool Change  124

  7.1.2 Tools with Longer Lives  126

  7.1.3 Automatic Process Diagnosis and Productions Process Adjustment  129

 7.2 Process Diagnosis Improvment Methods  131

 7.3 Process Adjustment and Process Recovery Improvement Methods  135

  7.3.1 Use of Redundant Machines  135

  7.3.2 Automatic Diagnosis: Adjustment and Recovery Systems  138

 7.4 Summary  140

     Problems  140

     References  147

8 Introduction to Preventive Maintenance  148

 8.1 Preventive Maintenance Schedules: Deviations on Both Sides of Target Values  150

 8.2 Prevetive Maintenance Schedules for Functional Characteristics  156

 8.3 Preventive Maintenance Schedules for Large Scale Systems  160

 8.4 Summary  162

     Problems  162

     References  163

Appendixes  165

 A Areas under the Normal Curve  165

 B Feed Forward Control  168

Index  171

Genichi Taguchi: Internaional Consultant

Dr. Genichi Taguchi is an international consultant in the field of quality control and assurance. He has served as Director of the Japnese Academy of Quality from 1978 to 1982. He was awarded the Deming Prize in 1960 in recognition of his contributuions in the development of various techniques for industrial optimization while he was on staff at Electrical Communication Laboratories of Nippin Telegraph and Telephone Public Corporation. From 1964 to 1981, he served as a professor at Aoyamagokuin University. Since 1981, he has served as a full time consultant to various companies such as AT&T, Bell Communications Research, Ford, Xerox, and many companies in the Unites States, Japna, Taiwan, and the People's Republic of China. Throughout the many years of his career, Dr. Taguchi has developed methods for on-line and off-line quality control which form the basis of his approach to a total quality control and assurance in a product's development cycle. Dr. Taguchi received his Doctor of Science from Kyushu University in 1962.

Elsayed A. Elsayed: Professor and Chairman, Department of Industrial Engineering, Rutgers University

Dr. Elsayed A. Elsayed is Professor and Chairman of the Department of Industrial Engineering, Rutgers University. His research interests are in the areas of quality and reliability engineering, production planning and control, and automated manufacturing systems. Dr. Elsayed held teaching and research positions at Cairo University, University of Windsor, and University of Utah. In 1987-1988, he spent his sabbatical with AT&T Bell Laboratories conductiong research on reliablity modeling and analysis of semiconductors. He served as a consultant to Bell Communivations Research, Sea-Land, Personal Products, AT&T, and other manufacturing companies. He is a coauthor of "Analysis and Control of Production Systems," Prentice-Hall, 1985. His is a senior member of IIE, ASME, SME, and ASEE and is listed in Who's Who in the East, and Who's Who in Engineering. Dr Elsayed received hos Ph.D. in industrial engineeering from University of Windsor in 1976. 

Thomas C. Hsiang: Director of Statisical Services Universal Foods Corporation

Dr. Thomas Hsiang is the Director - Statistical Services of Universal Foods Corporation, Milwaukee, Wisconsin, where he plays an integral role in training, consulting, and developing the implementation of all needed elements of the Total Quailty Effort throughout the company. He previously held positions in Quality and Statistics with various divisions in Bell Canada, AT&T, Bell Laboratories, and Bell Communications Research, where he served as a manager, teacher, and consultant in using statistics for the improvement of quality and productivity. He also taught at te Department of Statistics, Rutgers Universitym as an adjunct professor. He has had numerous publications in quality and statistics. He was cowinner of the Best Paper Award of the 1982 American Society for Qualith Control Congress. A native of Szechuan, China, Tom was educated in Taiwan and Canada, earning his B.S. (1965) in Chemical Engineering from Tunghai University; M. Eng. (1967) in chemical Engineering from McMaster University; and M. Math (1969) and Ph.D. (1971) in statistics from thr University of Waterloo. Tom is a member of the American Statistical Association (ASA) and the American Society for Quality Control (ASQC), and he is a registered Professional Engineer.

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