BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

Digital Learning
Part A: Content Design
Course Title

QUALITY CONTROL ASSURANCE & RELIABILITY

Course No(s)

ET ZC432

Credit Units

Credit Model

Unit split between Class Hours + Lab/Design/Fieldwork +

Student preparation

Course Author

Santanu P Datta

Version No

Enter version number

Date

JULY 29,2015

Course Objectives
No
CO1

To be acquainted to the modern thoughts on quality and

associated practices.

CO2

Learn the principles and techniques for quality control based on

statistical methods and learn the procedures for quality.

CO3

Be aware of the tools for quality engineering and quality

management. Gain knowledge of concepts of reliability and
methods to improve product and system reliability.

CO4

To enable practicing engineers to become successful managers in

a sustained manner to provide business houses the leading edge.

Text Book(s)
T1

Amitava
Mitra,
Fundamentals
of
Quality
Control
and
rd
Improvement, Wiley, 3 Edition, July 2008, ISBN: 978-0-47022653-7.

Reference Book(s) & other resources

R1

Douglas C. Montgomery, Introduction to Statistical Quality

Control, John Wiley & Sons, 3rd Ed., 2001.

R2

D.H. Besterfield et. al, Total Quality Management, Pearson

Education, 2nd Edition, 2001.

R3

Juran J.M. & F.M. Gryna, Quality Planning & Analysis, TMH, 3rd
Ed.,1995

Modular Content Structure

1. Introduction to Quality Control and the Total Quality System
1. Introduction and Objectives
2. Discussion on what is Quality and how its evolved
3. Quality, Quality control, Quality assurance and total quality system and
their Benefits
4. Quality circles and quality improvement teams, Customer needs and
market share
5. Quality and reliability
6. Quality improvement
7. Product and service costing
8. Quality costs
9. Measuring quality costs
10.
Management of quality
11.
Quality and productivity
12.
Total quality environmental management
13.
Case Study
2.

Some Philosophies and their Impact on Quality - I

1. Introduction and Objectives

2. W. Edwards Deming's Philosophy
1. Extended Process
2. Deming's 14 Points for Management
3. Deming's Deadly Diseases
3. Philip B. Crosby's Philosophy
1. Four Absolutes of Quality Management
2. 14-Step Plan for Quality Improvement
3. Joseph M. Juran's Philosophy
4. Quality Trilogy Process

5. Quality Planning, Control and Improvement

3.

Some Philosophies and their Impact on Quality - II

1. Introduction and Objectives

2. The Three Philosophies Compared
1. Definition of Quality
2. Management Commitment
3.
4.
5.
6.
7.
8.
9.
3. Case Study
4.

Strategic Approach to a Quality System

Measurement of Quality
Never-Ending Process of Improvement
Education and Training
Eliminating the Causes of Problems
Goal Setting
Structural Plan

Quality Management : Practices, Tools and standards

1. Introduction and Objectives

2. Management Practices
1. Total Quality Management
2. Vision and Quality Policy
3. Balanced Scorecard
4. Performance Standards
3. Quality Function Deployment and the process
4. Benchmarking and Performance Evaluation
1. Benchmarking
2. Quality Auditing
3. Vendor Selection and Certification Programs
4. Vendor Rating and Selection
5. Tools for Continuous Quality Improvement
6. International Standards ISO 9000, its Derivatives and other Industry
Standards
7. Malcolm Baldrige National Quality Award
1. Award Eligibility Criteria and Categories
2. Criteria for Evaluation
8. Case Study
5.

Fundamental of Statistical concepts (Probability)

1. Introduction and Objectives

2. Defining Population, Sample, Parameter and Statistic
3. Fundamentals of Probability
1. Relative Frequency Definition of Probability
2. Simple and Compound Events
3. Complementary Events
4. Additive Law
5. Multiplicative Law
6. Independence and Mutually Exclusive Events
4. Descriptive Statistics: Describing Product or Process Characteristics
1. Data Collection
2. Measurement Scales

6.

3. Measures of Central Tendency

4. Measures of Dispersion
5. Measures of Skewness and Kurtosis
6. Measures of Association
Techniques in Quality Control and Improvement

1. Introduction and Objectives

2. Probability Distributions
1. Cumulative Distribution Function
2. Expected Value
3. Discrete Distributions
4. Continuous Distributions
2. Inferential Statistics: Drawing Conclusions on
1. Product and Process Quality
2. Sampling Distributions
3. Estimation of Product and Process Parameters
4. Hypothesis Testing
7.

Graphical

methods

of

Data

presentation

and

quality

improvement
1. Introduction and Objectives
2. Data Analyses and Sampling
3. Empirical Distribution Plots
1. Histograms
2. Stem-and-Leaf Plots
3. Box Plots
4. Variations of the Basic Box Plot
3. Randomness of a Sequence: Run Chart
4. Validating Distributional Assumptions: Probability Plotting
5. Transformations to Achieve Normality: some Common, Power and Johnson
Transformation
6. Analysis of Count Data:
1. Hypothesis Test on Cell Probabilities
2. Contingency Tables
3. Measures of Association
7. Concepts in Sampling:
1. Sampling Designs and Schemes
2. Sample Size Determination
3. Bound on the Error of Estimation and Associated
4. Confidence Level
5. Estimating the Difference of Two Population Means
6. Estimating the Difference of Two Population
7. Proportions
8. Controlling the Type I & Type II Error
9. Associated Parameter Shift
8.

Statistical Process Control Using Control Charts

1. Introduction and Objectives

2. Causes of Variation: Special and Common

3. Statistical Basis for Control Charts

1. Basic Principles
2. Selection of Control Limits
3. Errors in Making Inferences from Control Charts
4. Effect of Control Limits on Errors in Inference Making
5. Warning Limits
6. Effect of Sample Size on Control Limits
7. Average Run Length
4. Selection of Rational Samples:
1. Sample Size
2. Frequency of Sampling
5. Analysis of Patterns in Control Charts
1. Some Rules for Identifying an Out-of-Control Process
2. Interpretation of Plots
3. Determination of Causes of Out-of-Control Points
6. Maintenance of Control Charts
9.

Control Charts for Variables - I

1. Introduction and Objectives

2. Selection of Characteristics for Investigation
3. Preliminary Decisions
1. Selection of Rational Samples
2. Sample Size
3. Frequency of Sampling
4. Choice of Measuring Instruments
5. Design of Data Recording Forms
4. Control Charts for the Mean and Range
1. Development of the Charts
2. Variable Sample Size
3. Standardized Control Charts
4. Control Limits for a Given Target or Standard
5. Interpretation and Inferences from the Charts
6. Control Chart Patterns and Corrective Actions
5. Control Charts for the Mean and Standard Deviation
1. No Given Standards
2. Given Standard
10. Control Charts for Variables - II
1. Introduction and Objectives
2. Control Charts for Individual Units
1. No Given Standards
2. Given Standard
3. Control Charts for Short Production Runs
1. and R Charts for Short Production Runs
2. Z-MR Chart
4. Other Control Charts
1. Cumulative Sum Control Chart for the Process Mean
2. Tabular Method

3. V-Mask Method
4. Cumulative Sum for Monitoring Process Variability
5. Moving-Average Control Chart
6. Exponentially Weighted Moving-Average or Geometric
7. Moving-Average Control Chart
8. Trend Chart (Regression Control Chart)
9. Modified Control Chart
10.
Acceptance Control Chart
5. Multivariate Control Charts
1. Controlling Several Related Quality Characteristics
2. Hotelling's T2 Control Chart and its Variations
3. Usage and Interpretations
4. Individual Observations with Unknown Process Parameters
5. Generalized Variance Chart
11. Control Charts for Attributes
1. Introduction and Objectives
2. Preliminary Decisions
3. Chart for Proportion Nonconforming: p-Chart
1. Construction and Interpretation
2. Variable Sample Size
3. Special Considerations for p-Charts
4. Chart for Number of Nonconforming Items: np-Chart
1. No Standard Given
2. Standard Given
5. Chart for the Number of Nonconformities: c-Chart
1. No Standard Given
2. Standard Given
3. Probability Limits
1. Chart for Number of Nonconformities per unit: u-Chart
2. Variable Sample Size and No Specified Standard
6. Chart for Demerits Per Unit: U-Chart
1. Classification of Nonconformities
2. Construction of a U-Chart
7. Charts for Highly Conforming Processes
1. Transformation to Normality
2. Use of Exponential Distribution for Continuous Variables
3. Use of Geometric Distribution for Discrete Variables
4. Probability Limits
8. Operating Characteristic Curves for Attribute Control Charts
12. Process Capability Analysis
1.
2.
3.
4.
5.
6.

Introduction and Objectives

Specification Limits and Control Limits
Process Capability Analysis
Natural and Statistical Tolerance Limits
Specifications and Process Capability
Process Capability Indices
1. Cp Index

2.
3.
4.
5.
6.

Upper and Lower Capability Indices

Cpk Index
Capability Ratio
Taguchi Capability Index, Cpm
Confidence Intervals and Hypothesis Testing on Capability

Indices
7. Comparison of Capability Indices
8. Effect of Measurement Error on Capability Indices
9. Gage Repeatability and Reproducibility
10.
Evaluation of Measurement Systems
11.
Metrics for Evaluation of Measurement Systems
12.
Preparation for a Gage Repeatability and Reproducibility
Study
13.

Cp Index and the Non-conformance Rate

14.
Process Capability Analysis Procedures and
Estimating Process Mean and Standard Deviation
7. Capability Analysis for Non-normal Distributions
1. Identification of Appropriate Distribution
2. Box-Cox Transformation
3. Using Attribute Charts
4. Using a Nonparametric Approach
8. Setting Tolerances on Assemblies and Components
1. Tolerances on Assemblies and Subassemblies
2. Tolerance Limits on Individual Components
3. Tolerance on Mating Parts
4. Nonlinear Combinations of Random Variables
9. Estimating Statistical Tolerance Limits of a Process
1. Statistical Tolerance Limits Based on Normal Distribution
2. Nonparametric Statistical Tolerance Limits
13. Acceptance Sampling Plans for Attributes and Variables - I
1. Introduction and Objectives
2. Advantages and Disadvantages of Sampling
3. Producer and Consumer Risks
4. Operating Characteristic Curve and Effect of the Sample Size and the
Acceptance Number
1. Sampling Plans: Types, Advantages and Disadvantages
5. Evaluating Sampling Plans
1. Average Outgoing Quality
2. Average Total Inspection
3. Average Sample Number
6. Bayes' Rule and Decision Making Based on Samples
14. Acceptance Sampling Plans for Attributes and Variables - II
1. Introduction and Objectives
2. Lot-by-Lot Attribute Sampling Plans, Single, Double, Multiple and Standard
Sampling Plans
3. Other Attribute Sampling Plans; Chain and Sequential Sampling Plans
4. Deming's kp Rule and Critique of the kp Rule

5. Sampling Plans for Variables and their Advantages and Disadvantages of

Variable Plans
7. Variable Sampling Plans for a Process Parameter; Estimating Process
Averages
8. Variable Sampling Plans for Estimating the Lot Proportion
9. Standard Deviation
10.
Standardized Plans: ANSI/ISO/ASQ Z1.9 and MIL-STD-414
15. Reliability
1. Introduction and Objectives
2. Reliability
3. Life-Cycle Curve and Probability Distributions in Modeling Reliability
1. Probability Distributions to Model Failure Rate
2. Availability
4. System Reliability, Systems with Components in Series, Parallel, Series and
Parallel, Standby.
5. Operating Characteristic Curves
6. Reliability and Life Testing Plans
1. Types of Tests
2. Life Testing Plans Using the Exponential Distribution
3. Standard Life Testing Plans Using Handbook H-108
16. Quality control in service sector
1. Introduction and Objectives
2. Service Industries and Their Characteristics
1. Differences in the Manufacturing and Service Sectors
2. Service Quality Characteristics
3. Measuring Service Quality
4. Techniques for Evaluating Service Quality
3. Model for Service Quality
4. Case study
Learning Outcomes:
No

Learning Outcomes

LO1

Learner will become a technically competent person, well versed

in statistical quality control having Statistical foundations to realworld situations and pertinent issues of manufacturing and
service sectors.

LO2

Learner will understand and exhibit fundamentals of quality

control, quality costs, their measurement, analysis and various
tools for quality improvement.

LO3

Learner will be aware of philosophies of leading quality experts

as well as Quality Awards and Standards.

LO4

Learner will be able to formulate some common sampling

designs; determine an appropriate sample size; set tolerances on

assemblies and components and practice acceptance sampling
procedures.
LO5

Learner will understand the Reliability and the improvement

methods, selection of parameters for warranty and use of life
testing plans.

Part B: Learning Plan

Academic Term

SECOND SEMESTER 2015-16

Course Title

QUALITY CONTROL ASSURANCE & RELIABILITY

Course No

ET ZC432

Lead Instructor

Santanu P Datta

Contact Hour 1&2

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre
CH

T1- Chapter
1

Basic knowledge about

Quality in Industry and
Services

Past Experience,T1

Durin
g CH

T1- Chapter
1

Introduction to Quality
Control and Total Quality
System

T1

Post
CH

T1- Chapter
1
Data from
Industry

Relate the gained

knowledge to day to day
activity in the
Manufacturing/Service
unit(s).

T1 and Industry where

working.

Contact Hour 3&4

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre
CH

T1- Chapter
2

Read the basics of

Deming and Philip
Crosbys Philosophy

Internet

Durin
g CH

T1- Chapter
2

Some Philosophies and

their Impact on Quality - I

T1

Post
CH

T1- Chapter
2
Data from
Industry

Compare and Contrast

the Philosophy of
Deming, Juran and Philip
Crosby

T1, Internet, Day to Day

Service Providers and
Industry where working.

Contact Hour 5&6

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Chapter 2

Summary of Philosophy
of Deming, Juran and
Philip Crosby

Internet

During
CH

T1Chapter 2

Some Philosophies and

T1

their Impact on Quality II

Post
CH

T1Chapter 2
Data from
Industry

Write an assignment on
the implementation of
the learned philosophy in
real life
Manufacturing/Service
unit.

T1, Internet, Day to Day

Service Providers and
Industry where working.

Contact Hour 7&8

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Chapter 3

Acquire basic knowledge

of Vision, Mission, Goals,
Vendors, International
Standards etc.

Internet and Industry where

working

During
CH

T1Chapter 3

Quality Management:

T1

Practices, Tools and

standards

Post
CH

T1Chapter 3
Data from
Industry

Class to be divided in
various groups and asked
to use the tools for
various operations
performed in the Industry

T1 and Industry where

working

Contact Hour 9&10

Type

Content
Ref.

Topic Title

Pre CH

T1Chapter 4

Revising the basics

studied in school

Study/HW Resource
Reference
T1 and Internet

During
CH

T1Chapter 4

Fundamental

of T1

Statistical

concepts

(Probability)
Post
CH

T1Chapter 4
Data from
Industry

Assignments on basic
problems related to the
topic

T1 and Industry where

working

Contact Hour 11&12

Type

Content
Ref.

Topic Title

Pre CH

T1Chapter 4

A strong base of basic

probability

During
CH

T1Chapter 4

Techniques

Post
CH

T1Chapter 4
Data from
Industry

Assignments on basic
problems related to the
topic

in

Study/HW Resource
Reference
T1 and Internet

Quality T1

Control and Improvement

T1 and Industry where
working

Contact Hour 13&14

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Chapter 5

Data Analysis and

Sampling

T1 and Internet

During
CH

T1Chapter 5

Graphical methods of
Data presentation and
quality improvement

T1

Post
CH

T1Chapter 5
Data from
Industry

Assignments on problems T1 and Industry where

related to the topic
working

Contact Hour 15&16

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Chapter 6

Understanding what is
Quality, Process
capability, Variability in
any process and what is
the need and means of
controlling the process.

T1 and Internet

During
CH

T1Chapter 6

Statistical Process Control T1

Post
CH

T1Chapter 6
Data from
Industry

Assignments on problems T1 and Industry where

related to the topic
working

Using Control Charts

Contact Hour 17&18

Type

Content
Ref.

Topic Title

Pre CH

T1Chapter 7

Fundamentals of Control
Chart

During
CH

T1Chapter 7

Control

Post
CH

T1Chapter 7
Data from
Industry

Assignments on problems T1 and Industry where

related to the topic
working

Charts

Study/HW Resource
Reference
T1 and Internet

for T1

Variables I

Contact Hour 19&20

Type

Content
Ref.

Topic Title

Pre CH

T1Chapter 8

Fundamentals of Control
Chart

During
CH

T1Chapter 8

Control

Post
CH

T1Chapter 8
Data from
Industry

Assignments on problems T1 and Industry where

related to the topic
working

Charts

Study/HW Resource
Reference
T1 and Internet

for T1

Variables II

Contact Hour 21&22

Type

Content
Ref.

Topic Title

Pre CH

T1Chapter 8

Fundamentals of Control
Chart

During
CH

T1Chapter 8

Control

Post
CH

T1Chapter 8
Data from
Industry

Assignments on problems T1 and Industry where

related to the topic
working

Charts

Study/HW Resource
Reference
T1 and Internet

for T1

Attributes

Contact Hour 23&24

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Chapter 9

Statistical Process
control. Fundamentals of
measuring instrument,
measures of precision of
the instrument as well
as the impact of various
operators who use the
instrument and
appropriate measures.

T1 and Internet

During
CH

T1Chapter 9

Process capability
analysis

T1

Post
CH

T1Chapter 9
Data from
Industry

Assignments on Case
studies and Numericals
based on:
The determination of the
inherent process
capability.
Capability analysis of
processes that are in
control.
Inference on ability of
process to produce items
that conforms to desired
specifications.
Determination of process
mean and spread for one
and two sided

T1 and Industry where

working

specification limits.
Various measures of
Process capability.
Proportion of non
conforming product and
other related problems.

Contact Hour 25&26

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Need of Sampling,
Chapter 10 Benefits and Limitations

T1 and Internet

During
CH

T1Acceptance sampling
Chapter 10 plans

T1

Post
CH

T1Chapter 10
Data from
Industry

T1 and Industry where

working

Discussions on how prior

information along with
information from the
sample selected can be
used to make decisions
by implementing
methods of process
control and improvement

Contact Hour 27&28

Type

Content
Ref.

Topic Title

Study/HW Resource
Reference

Pre CH

T1Basics of Acceptance
Chapter 10 Sampling

T1 and Internet

During
CH

T1Acceptance sampling
Chapter 10 plans for attributes and
variables

T1

Post
CH

T1Assignments on problems T1 and Industry where

Chapter 10 related to the topic
working
Data from
Industry

Contact Hour 29&30

Type

Content

Topic Title

Study/HW Resource

Ref.

Reference

Pre CH

T1Basics of Warranty and

Chapter 11 its policy. Concept of
Sampling plans and
Reliability.

T1 and Internet

During
CH

T1Reliability
Chapter 11

T1

Post
CH

T1Chapter 11
Data from
Industry

Case studies and

T1 and Industry where
Assignments on problems working
related to the
determination of
Reliability, how to
improve it, selection of
parameters for warranty
and use of reliability and
life testing plans and
develop parameter
estimates through
sampling plans.

Contact Hour 31&32

Type

Content
Ref.

Topic Title

Pre CH

T1Chapter 2

Fundamentals of Quality
and its Control and
concepts of Service
Sector

T1 and Internet

During
CH

T1Chapter 2

Quality control in service

sector

T1

Post
CH

T1Chapter 2
Data from
Industry

Assignments on Case
studies related to above
topic

T1 and Industry where

working

Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After
No
Name
Type
Durati
on
ECQuiz-I/ Assignment-I
Online
1
Quiz-II
Quiz-III/ AssignmentII
ECMid-Semester Test
Closed
2
2
Book
hours

Study/HW Resource
Reference

Noon Session; FN = Fore Noon Session

Weig Day, Date, Session, Time
ht
5%
February 1 to 10, 2016
5%
5%

March 1 to 10, 2016

March 25 to April 3, 2016

35%

27/02/2016 (FN) 10 AM 12
Noon

EC3

Comprehensive
Exam

Open
Book

3
hours

50%

09/04/2016 (FN) 9 AM 12 Noon

Syllabus for Mid-Semester Test (Closed Book): Topics in Session Nos. 1 to 16

Syllabus for Comprehensive Exam (Open Book): All topics (Session Nos. 1 to 32)
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the
latest announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the
Elearn portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them
through the course pages on the Elearn portal. Announcements will be made on the portal,
in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or
bound) is permitted. However, loose sheets of paper will not be allowed. Use of calculators
is permitted in all exams. Laptops/Mobiles of any kind are not allowed. Exchange of any
material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the
student should follow the procedure to apply for the Make-Up Test/Exam which will be
made available on the Elearn portal. The Make-Up Test/Exam will be conducted only at
selected exam centres on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study
schedule as given in the course handout, attend the online lectures, and take all the prescribed
evaluation components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam
according to the evaluation scheme provided in the handout.