Govt.

Polytechnic, Mumbai

Rubber Technology

METROLOGY AND QUALITY CONTROL

PROGRAMME : Rubber Technology Compulsory Prerequisite Credit Optional L P Total Examination scheme Theory TH TS PR OR TW Total Course Code

Course Title

ME Metrology and C 4 2 6 80 20 07401 Quality Control 1. Theory papers duration 3 hrs. 2. Theory paper assessment is internal and external. 3. The assessment of practical, oral, term work is internal except mark (*). 4. (*) The assessment is internal and external. 5. C = Compulsory, O = Optional.

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RATIONALE: Metrology is the science of measurement. Technician working in industries should understand various instruments used. The subject impart the necessary knowledge so that student can select & use various instrument used for measurement. ISO 9000 emphasizes on the quality system and total quality management the success of any industry depends on Quality of its product. Technician placed in Quality control or Inspection department has to take various decisions such decision of a acceptance or rejection. Investigating reasons for defects and giving suggestion etc. The subject imparts necessary knowledge so that student can perform the job of quality control supervisor effectively and efficiently. OBJECTIVES: By the end of this course the student will able to: Develop the ability of analysis interpretation and drawing conclusions the data / instrument / graph / chart pertaining to the area of quality control. Develop an ability of problem solving and decision making. Plot and use of quality control charts. Suggest measures to improve the quality of product and reduce cost. To understand the quality system ISO-9000 Understand the salient concept and principles required to develop the ability of using different types of measuring instrument. Understand the principles, construction and use of various measuring instruments. Understand the techniques of handling and maintaining measuring instrument. SECTION - I (P-32, M-40) 1. Measuring Instrument (P-06, M-07) a. Definition, need of inspection, precision, accuracy, sensitivity amplification magnification errors, sources of errors. b. Construction, working and method of use for simple measuring instruments like calipers, surface plate, angle plate, V block different types of micrometer vernier slip gauges. c. Standards of measurements, line and end standard, wavelength std. ME07401 (Provisional) Page 1 of 4

Govt. Polytechnic, Mumbai

Rubber Technology

2. Angular Measurements (P-04, M-06) Angular measurement by instrument such as universal bevel protractor, spirit level, sine bars, censers, angle Decker, autocollimator angle gauges. 3. Limits Fits and Tolerances (P-06, M-09) Limits-fits-gauges definitions-tolerance-fit, deviation, basic shaft, hole. Taylors principle-limit gauges, elementary study of gauge-design (I.S.919-1963) 4. Measurements (P-06, M-09) a. Measurements by comparison: Comparators Mechanical, electrical, electronic, optical and pneumatic. b. Dial indicators, types, construction and working. 5. Testing Methods (P-10, M-09) a. Straightness testing by straight edge spirit level auto-collimator b. Flatness testing by straightness testing techniques and by optical flats. c. Square ness testing by dial indicators. d. Parallelism testing between two axes, two planes one plane stationary other moving axis of rotation and trajectory. e. Roundness testing by dial indicator roundness testing machine. f. Roughness testing-Terminology C.L.A., R.M.S. Values g. Stylus probe instruments. Tomlinsons surface meter. SECTION II (P-32, M-40) 6. Quality Control (P-08, M-07) a. Meaning of quality control difference between quality of design, quality of conformance and quality of performance concept of reliability and maintainability. b. Quality policy, quality of objectives economics of quality, cost and value, quality specification. c. Quality maintenance assurance, quality audit, quality vendor rating, organization set up for quality. d. Inspection and quality control difference between inspection and quality control inspection stations. 7. New trends in Quality Management (P-05, M-07) a. Quality circles-basic concept, purpose and functioning. b. Concept of TQM. c. Concept of KAIZEN d. Concept of POKAYOKE. e. ISO-9000 8. Fundamental of Statistical Quality Control (P-06, M-07) a. Importance of statistics in quality control. b. Frequency distribution mean, medium, mode, range, standard deviation and variance construction and normal distribution curve, interpretation area under the normal. ME07401 (Provisional) Page 2 of 4

Govt. Polytechnic, Mumbai

Rubber Technology

9. Control charts (P-08, M-13) a. Charts for variables-X chart R chart b. Control charts for attributes. P chart C chart c. Process capability of a machine-Statistical limits, tolerance limits, different possibilities, rejection areas, capable-incapable process. 10. Acceptance sampling (P-05, M-06) Q.C. curve, its important characteristics sampling, risks, single-double sampling plans, advantages disadvantages of Sampling. Laboratory Works: Laboratory experience should develop the following skills / abilities:1. A skill in handling different measuring instruments. 2. Ability in planning and setting experiment work to measure the given production job. 3. Ability of selecting measuring instruments. 4. Ability of investigating defects / errors or locating, faults and suggesting remedial measures. 5. Ability of collecting, analyzing and interpretation of data. 6. Ability of problem solving and decision making. 7. Attitude of inquiry. 8. Safety and cost consciousness. 9. Ability of using different control charts. The laboratory work should be supported by frequents visits to industries to get the practical experience. It is desirable that simple production jobs from the industries are included as laboratory exercises. For inspection simple problems from the industries can also be given to the students to find out alternatives. 1. Use of various basic measuring instruments-steel rule, hand calipers, surface plate, angle plate, V-block, radius-feeler-pitch screw gauge, spirit level, combination set, straight edge, universal surface gauge, engineering square. Internal telescopic gauge, vernier calipers, vernier height gauge, internal external micrometer, micrometer depth gauge. 2. Measurement of dimensions of actual components using instrument of experiment No.-1. Measure the dimensions of at least five components by using various instruments. Justify for the difference in readings when it dim is measured by caliper, vernier and micrometer (i.e. the instruments of difference categories) 3. Use of slip gauges- Write the details of slip gauge set observed. Understand the method of wringing. Build a required dimension with the help of available slips. Sketch-the accessories like holder with measuring jaws. Understand its use. Measure unknown gap with slip. 4. Use of Dial Indicator-uses classification as per I.S. specifications. 5. Use of mechanical (any one type) Pneumatic Comparators with the help of slip gauges / ring gauges. Measure the unknown dimensions. 6. Use of sine bar to find unknown angle using slip gauges. Compare this angle with that obtained by bevel protractor. 7. Use of optical profile projector- measure suitable parameters of a small screw check the profile of the component (gear, screw thread) supplied. ME07401 (Provisional) Page 3 of 4

Govt. Polytechnic, Mumbai

Rubber Technology

8. Use of optical flat for flatness testing- check whether the surface of slip gauge is perfectly flat or not note the precautions taken with monochromatic source of light. Sketch the fringe pattern observed. Predict the fringe pattern with convex / concave surface write how this techniques is suitable for parallelism testing screw. 9. Construction of control charts- for variable measurements (X, R chart) Take readings. Draw the control charts on graph. Interpret results. Suggest the options if any. 10. Construction of control charts for Attribute measurements (p. chart) takes readings, show them it on graph. Interpret results and suggest the change to be done if any. 11. Determination of process capability of a machine- (Actual testing of machine or process be done if possible) Give procedure to know process capability of a machine with three sigma and tolerance limits on normal distribution curve. Give different possibilities. Reference Books 1. Engineering Metrology R.K. Jain 2. Metrology and Quality control M.S. Mahajan 3. Hand book of Industrial Metrology ASTME. 4. Metrology Lab manual M. Addith and R. Bahl (T.T.T.I.) 5. Quality planning and analysis Juran 6. Hand book industrial engg. H.B. Maynard 7. Quality Control M.S. Mahajan 8. Total Quality Control Feigenbaum 9. Quality Control TTTI, Madras 10. Quality Control Grant, Leavenworth 11. ISO-9000-Brian Rothery 12. Metrology and Quality Control R.K. Jains

ME07401 (Provisional)

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