Pusa Institute of Technology

New Delhi - 110012

INSPECTION AND QUALITY CONTROL

PROJECT

Submitted By: Submitted To:

Navneet Kumar Singh
Kritik Kumar
Navneet Mr. Bharat Singh Yadav
1408131071
1508131223 IQC Lecturer
Mechanical Morning
Mechanical Evening
5th Sem/ PASSOUT

5th Semester / 3rd Year

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 Contents

CHAPTER - 1 INTRODUCTION................................................................................................. 3
CHAPTER - 2 EXPERIMENTS PERFORM................................................................................ 5
EXPERIMENT – 1...................................................................................................................... 5
EXPERIMENT - 2…..………………………………………………………………………….7
EXPERIMENT - 3…………………………………………………………………………….10
EXPERIMENT – 4.................................................................................................................. 122
EXPERIMENT– 5................................................................................................................... 144
EXPERIMENT-6 .................................................................................................................... 166
CHAPTER - 3 CONCLUSION ................................................................................................... 20
REFERENCE……………………………………………………………………………...24

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 CHAPTER - 1 INTRODUCTION

SHAPES INDUSTRIES
An ISO 9001: 2008 certified company specializes in sheet metal components and tubular parts.
Our totally focused on performance.Our turnover is INR 4.0 Cr/ year. We have 10 Executive
staff and we feature in the list of 5000 automobile components manufacturers in India.

PLANT AREA:

 This company is constructed in10000 sq. feet & has 5000 sq. feet open ground.

 The company follows stringent quality norms to produce high quality of products to
supply its reputed customers.

VISSION & MISSION:

Highly customer oriented human and system run global organization with a concern for society.
We are a dedicated, proactive, loyal & accountable group of people with a quest for excellence

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through latest technology, people empowerment and brand equity to produce world class
products by adopting best business practices and ethics.”

QUALITY POLICY:

We are committed for customer satisfaction by providing quality products and service through-

 Timely response to customer requirement.

 Continual up gradation of our technology.
 MATERIAL: SP as per JIS: G-3141
 ALT. MATL: HRCS Sheet, Type-D, as per IS: 1079 Thickness: 3.2mm
 JIS G 3141 is a Japanese material standard for Cold Rolled Steel.
 HRCS – Hot Rolled Carbon Steel sheet

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 CHAPTER - 2 EXPERIMENTS PERFORM

EXPERIMENT – 1
Aim: To calculate Mean, Median, Mode, Standard Deviation and Variance.

Theory:
……
1. Mean (𝑥̅ ) = mm.
2. Median = In ascending or descending order, the middle value is median.
3. Mode = Maximum Frequency.
∑( ̅)
4. Standard deviation (𝜎) = mm.

5. Variance = σ ²mm.

Observation Table:

SLOT SIZE
S.NO. LENGTH (mm) BREADTH (mm)
1 18 8
2 18 8
3 18 8
4 18.1 8
5 18.2 8
6 18 8
7 18.1 8
8 18 8.2
9 18 8
10 18 8
11 18 8
12 18 8
13 18 8
14 18 8.1
15 18 8
16 18 8
17 18 8
18 18.1 8
19 18 8
20 18 8
21 18 8
22 18.1 8

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 23 18 8
24 18 8.1
25 18 8
26 18 8.2
27 18 8
28 18 8
29 18 8
30 18 8.1

For Length:

1. Mean (𝑥̅ ) = 18.02

2. Median = 18
3. Mode = 18
4. Standard Deviation (𝜎) =0.0022
5. Variance =0.00000484

For Breadth:

1. Mean (𝑥̅ ) = 8.0233

2. Median = 8.1
3. Mode = 8
4. Standard Deviation (𝜎) =0.009
5. Variance =0.000081

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 EXPERIMENT – 2

Aim: To calculate ‘𝒙’ and ‘R’ chart for a given set of component.

Theory:

For 𝒙 chart:

𝒙𝐜𝐡𝐚𝐫𝐭:It shows the variation in the average of samples.

Upper control limit (UCL𝒙): 𝒙 + 𝑨𝟐 𝑹

Lower control limit (LCL𝒙):𝒙 − 𝑨𝟐 𝑹

A2= 0.73,
For R chart:
D3= 0,
R chart: It shows the variation in the range of samples.
D4= 2.28
Upper control limit (UCLR): 𝑹𝑫4

Lower control limit (LCLR): 𝑹𝑫3

Observation Table:

S.NO. SUBGROUP n=4 (mm) MEAN (X-bar) RANGE

1 18 18.1 18 18 18.025 0.1
2 18 18 18 18 18 0
3 18.1 18.1 18 18 18.05 0.1
4 18 18 18 18 18 0
5 18 18 18 18 18 0
6 18 18 18 18.2 18.05 0.2
7 18 18 18 18 18 0
8 18 18.1 18 18 18.025 0.1
9 18 18 18 18 18 0
10 18 18 18 18 18 0
11 18 18 18 18 18 0
12 18 18 18 18.2 18.05 0.2
13 18 18 18 18 18 0
14 18 18 18 18 18 0
15 18 18.1 18.1 18 18.05 0.1
16 18 18 18 18 18 0
17 18 18 18 18 18 0
18 18 18 18 18 18 0
19 18 18 18 18 18 0

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20 18 18 18 18 18 0
21 18 18 18 18 18 0
22 18.1 18 18 18 18.025 0.1
23 18 18 18 18.1 18.025 0.1
24 18 18 18 18 18 0
25 18 18.2 18 18 18.05 0.2
26 18 18 18 18 18 0
27 18.2 18 18 18 18.05 0.2
28 18 18 18 18 18 0
29 18 18 18 18 18 0
30 18 18 18 18 18 0

X-BAR
18.06

18.05

18.04

18.03

18.02

18.01

18

17.99

17.98

17.97
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

MEAN (X-bar) X-BAR UCLx ̅

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 R-BAR
0.25

0.2

0.15

0.1

0.05

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

RANGE R-BAR UCLr LCLr

Result: The value of 𝑥̅̅ =18.0133 and 𝑅 = 0.0467

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 EXPERIMENT – 3

Aim: To construct P-chart for a given set of components.

Theory: In statistical quality control, the P-chart is a type of control chart used to monitor the
proportion of non-conforming units in a sample, where the sample proportion non-conforming is
defined as the ratio of the number of non-conforming units of the sample size.
⋯
𝑃=

Observation Table:

S.NO. SAMPLE SIZE NO. OF DEFECTED P=DEFECTED/INSPECTED

(n) PIECE
1 50 1 0.02
2 60 0 0
3 40 0 0
4 70 0 0
5 70 0 0
6 85 0 0
7 40 1 0.025
8 45 0 0
9 50 0 0
10 60 0 0
11 50 0 0
12 50 0 0
13 60 0 0
14 50 0 0
15 90 0 0
16 95 4 0.042
17 85 0 0
18 80 0 0
19 75 0 0
20 70 0 0

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 21 50 1 0.02
22 40 0 0
23 40 0 0
24 40 2 0.05
25 70 0 0
26 60 0 0
27 90 0 0
28 55 0 0
29 60 1 0.017
30 65 3 0.046

P-CHART
0.14

0.12

0.1

0.08

0.06

0.04

0.02

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

P=DEFECTED/INSPECTED P-BAR UCLp LCLp

Result: The value of 𝑝̅ = 0.01, UCL = 0.13, LCL = 0.

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 EXPERIMENT – 4

Aim: To construct nP-chart for a given set of components.

Apparatus Required: Vernier Calliper and set of components.

Theory: Whenever subgroup size is variable, control chart for fraction defective (P) chart is
used. However, if subgroup size is constant the chart for actual number of defectives known as
np-chart is preferred over p-chart. As np-chart saves one calculation for each subgroup the
division of numbers of defective by subgroup are to get fraction defective P. As np-chart helps us
to visualize broadly on the chart.

𝑛𝑝̅
𝑝̅ =
𝑛

UCL 𝑛𝑝̅ = 𝑛𝑝̅ + 3√𝑛𝑝̅ (1 − 𝑝̅ )

LCL 𝑛𝑝̅ = 𝑛𝑝̅ − 3√𝑛𝑝̅ (1 − 𝑝̅ )

Observation Table:

S.NO. SAMPLE SIZE NO. OF

(n) DEFECTS (Np)
1 100 0
2 100 0
3 100 0
4 100 0
5 100 0
6 100 0
7 100 2
8 100 0
9 100 0
10 100 0
11 100 1
12 100 4
13 100 0
14 100 0
15 100 0
16 100 0
17 100 2
18 100 0
19 100 0

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 20 100 0
21 100 0
22 100 0
23 100 1
24 100 0
25 100 0
26 100 0
27 100 0
28 100 0
29 100 0
30 100 0

NP CHART
defects UCLnP LCLnP Mean

4
NO. OF DEFECTS

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
NO. OF INSPECTED LOT

Result: The value of 𝑛𝑝̅ = 0.333, UCL = 5.146, LCL = 0.

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 EXPERIMENT– 5
Aim: To construct C-chart for a given set of components.

Theory: it is also called ‘Defect chart’. An item is said to be defective, if it fails to perform or
conform to the specifications in any of the characteristics. Each characteristic that does not meet
the specification is a ‘defect’. An item is defective if it contains at least one or more defects.

UCLC= 𝑪 + 𝟑√ 𝑪, LCLC =𝑪 − 𝟑√ 𝑪

Observation Table:

S.NO. OF TOTAL NUMBER OF

SAMPLE DEFECTS IN EACH
SAMPLE
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 1
10 0
11 0
12 1
13 0
14 0
15 0
16 2
17 0
18 0
19 0
20 0
21 0
22 0
23 0
24 0
25 0
26 0
27 0
28 2
29 0
30 1
31 0

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 32 0
33 0
34 0
35 0
36 0
37 1
38 0
39 0
40 0
41 0
42 0
43 0
44 0
45 2
46 0
47 0
48 0
49 0
50 1

C-CHART
2.5

1.5

0.5

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

TOTAL NUMBER OF DEFECTS IN EACH SAMPLE C-BAR UCLc LCLc

Result: The value of 𝐶̅ = 0.22, UCL = 1.63, LCL = 0.

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 EXPERIMENT-6

Aim: To construct OC (Operating Characteristics) curve for a given set of components.

Apparatus Required: Vernier Calliper and set of components.

Theory: The operating characteristics curve for an attribute sampling plan is a graph of fraction
defective in a lot against the probability of acceptance. For any fraction defective p’ in a
submitted lot, the OC curve shows the probability Pa that such a lot will be accepted by the
sampling plan. In single sampling plan three parameters are specified.

N = lot size from where samples are drawn,

n = sample size
C = acceptance,
𝝀 = poison’s ratio

Observation Table:

Acceptance N Defects P n 𝝀 P(a)th. 1 2 3 4 5 P(a)act.

(D)
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.81 0 0 0 0 1 0.8
C=0 100 2 0.02 20 0.4 0.67 0 1 0 1 0 0.6
100 3 0.03 20 0.6 0.54 0 2 0 0 1 0.4
100 4 0.04 20 0.8 0.44 1 1 1 1 0 0.2
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.97 1 0 0 0 0 0.8
C=1 100 2 0.02 20 0.4 0.93 0 2 0 0 0 0.8
100 3 0.03 20 0.6 0.864 0 1 2 0 0 0.6
100 4 0.04 20 0.8 0.792 0 1 0 1 2 0.4
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.986 1 0 0 0 0 0.8
C=2 100 2 0.02 20 0.4 0.983 0 0 1 0 1 0.6
100 3 0.03 20 0.6 0.962 0 0 1 0 2 0.6
100 4 0.04 20 0.8 0.935 0 2 0 1 1 0.4
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.987 0 0 1 0 0 0.8
C=3 100 2 0.02 20 0.4 0.99 0 0 1 1 0 0.6
100 3 0.03 20 0.6 0.981 0 1 2 0 0 0.6
100 4 0.04 20 0.8 0.973 0 1 1 1 1 0.2
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.987 0 0 1 0 0 0.8
C=4 100 2 0.02 20 0.4 0.99 0 0 2 0 0 0.8
100 3 0.03 20 0.6 0.983 1 0 1 1 0 0.4

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 100 4 0.04 20 0.8 0.98 1 0 1 1 1 0.2

C=0
1.2

1
Probability Acceptance

0.8

0.6

0.4

0.2

0
1 2 3 4 5
Defective Fraction

P(a) Theoretical P(a) Practical

C=1
1.2

1
Probability Acceptance

0.8

0.6

0.4

0.2

0
1 2 3 4 5
Defective Fraction

P(a) Theoretical P(a) Practical

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 C=2
1.2

1
Probability Acceptance

0.8

0.6

0.4

0.2

0
1 2 3 4 5
Defective Fraction

P(a) Theroretical P(a) Practical

C=3
1.2

1
Probability Acceptance

0.8

0.6

0.4

0.2

0
1 2 3 4 5
Defective Fraction

P(a) Theoretical P(a) Practical

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 C=4
1.2

1
Probability Acceptance

0.8

0.6

0.4

0.2

0
1 2 3 4 5
Defective Fraction

P(a) Theoretical P(a) Practical

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 CHAPTER - 3 CONCLUSION
From all above experiments we come to know, when all the points fall inside the control
limits; we say that the process is in control. It really means for all practical purposes it acts
as if no assignable causes of variation a present. Based on how many points fall outside the
control limits, 1 out 35 points or 2 out of 100 points can also be tolerated and the process is
said to be in control. If points fall outside more than the control limit is said to be out of
control, company is in risk or loss.

Experiment 1: - Conclusion for calculate Mean, Median, Mode, Standard deviation and
variance: -

For Length:

6. Mean (𝑥̅ ) = 18.02

7. Median = 18
8. Mode = 18
9. Standard Deviation (𝜎) =0.0022
10. Variance =0.00000484

For Breadth:

6. Mean (𝑥̅ ) = 8.0233

7. Median = 8.1
8. Mode = 8
9. Standard Deviation (𝜎) =0.009
10. Variance =0.000081

Merits: -

1. Calculation was easy to find the average value. From the average value, we can see
that the piece is near to mean value or not.
2. From the calculation of standard deviation, we can also check the system is in risk or
not.

Demerits: -

1. If there is any wrong value in measurement instrument then all values will be wrong.
2. If worker has no knowledge about instrument, then data will be worng.

Experiment 2: - Conclusion for 𝑥̅ and R chart: -

1. All the values of 𝑥̅ are under UCL, this means the chat is correct.

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 2. Any value is not touching LCL.
3. All the values of R are under the UCL, it means the calculation and chart are correct.

Merits: -

1. This control chart is used to monitor variables data when samples are collected at
regular intervals from a business or industrial process.
2. The sample size is relatively small.

Demerits: -

1. The X̅ chart is only valid if the within sample variability is constant.

Experiment 3: - Conclusion for P chart: -

1. All the value of P is under the UCL.

2. Maximum value is near to P̅.

Merits: -

1. P chart is used for both where number of inspection is constant or variable.

2. P chart is best suited in cases where inspection is carried out with a view of classifying
an article as accept or reject.

Demerits: -

1. Special training.
2. Misplaced control limits.

Experiment 4: - Conclusion for np chart: -

1. All the values of np are below the UCL.

2. Maximum value is near to CL (np̅).

Merits: -

1. It is a zoom chart of P chart.

2. np chart saves one calculation for each subgroup.

Demerits: -

1. It is used only where, there the sample size is constant.

Experiment 5: - Conclusion for C chart: -

1. No values of C chart cross the UCL.

2. Maximum value is on the LCL.

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 3. Few values are also near the CL.

Merits: -

1. In this each operation pieces are inspected.

2. The C-chart technique helps to keep these defect per unit at minimum level.

Demerits: -

1. For checking every piece more time is required.

Experiment 6: - Conclusion for OC Curve

1. As the number of acceptance increases, the theoretical Pa line will tend to become
straight.
2. As the acceptance number is increased the practical line Pa will tend to bend.

Merits: -

1. The method is applicable in those industries, where mass production and the industries
follow a set production procedure.
2. The method is economical and easy to understand.
3. Cause less fatigue boredom.
4. Computation work involved is comparatively very small.
5. The people involved in inspection can be easily imparted training.
6. Products of destructive nature during inspection can be easily inspected by sampling.
7. Due to quick inspection process, scheduling and delivery times are improved.

Demerits: -

1. It does not give 100% assurance for the confirmation of specification so there is
always some likelihood/risk of drawing wrong inference about the quality of the batch.
2. Success of the system is dependent on, sampling randomness, quality characteristic to
be tested, batch size and criteria of acceptance of lot.

S. No. Variable Charts Attribute Charts

1 Advantages:
 Provides maximum utilisation of  Data required are often already
information available from data. available from inspection records.
 Provides detailed information on  Easily understood by all persons.
process average and variation for Since, it is simpler as compared to 𝑥̅
control of individual dimensions. and R chart.

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2 Disadvantages:
 They are not easily understood
unless training is provided.
 Can cause confusion between
control limits and specified limits.
 Cannot be used with go-no-go type
gauge inspection.
3 𝒙and R chart is best for variable data
because they show average and
variations.
 It provides overall picture of quality
history.
 They do not provide detailed
information for control of individual
characteristic.
 They do not recognise different
degree of defectives.
(Weightage of defects).
Np chart is best for attribute data
because it shows number of defected
pieces.
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 Reference

1. Book
2. Experiment file
3. Data is take from Shapes Industries.

Vineet
Contact: 9015803053
Address: VillMohammadpurJhasa, PO. Narsinghpur, Sec-36, Old Manesar
Road, Gurgaon, Haryana, India.

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