UNIVERSITY OF BRIDGEPORT



UNIVERSITY OF BRIDGEPORT

School of Engineering

FALL 2016

COURSE OUTLINE

TCMG 524-DL

Statistical Quality Control Techniques

Semester Offered: Fall 2016 Instructor: Elif Kongar

Course Number: TCMG 524 DL Office: 141 TECH

Credit Hours: 3 SH E-mail: kongar@bridgeport.edu

Office Hours: Tuesday : 1:00 – 3:00 PM Phone: (203) 576-4379

Thursday : 3:00 – 5:00 PM

Course Description:

This course presents a comprehensive summary of methods for managing quality and continuous process improvements. The course objective is to develop an operational familiarity with contemporary methods found to be effective. This course is intended for those students who do not plan to specialize in quality management.

• Topics include: Statistical process control, quality function deployment, concurrent design, the house of quality, the Taguchi method, Six Sigma, lean and others. It also covers continuous process improvement methodologies and techniques.

Course Prerequisites:

• Basic knowledge of probability and statistics.

• Basic computer programming experience.

• General spreadsheet skills and familiarity with industrial engineering, operations research, and manufacturing systems

Course Objectives:

Successful completion of the course will provide:

1. Demonstrating a comprehensive understanding of the modern statistical methods for quality control and improvement.

2. An understanding of integrated and comprehensive models for TQM, Six Sigma, and TQS.

3. An understating of preventing, detecting, and analyzing the root cause of problems in manufacturing.

Course Topics:

• Introduction to basic concepts of quality improvement and quality control

• An overview of Total Quality Management (TQM)

• Six-Sigma Process and the DMAIC Roadmap

• Modeling process quality

• Just in Time (JIT) Manufacturing / Agile Manufacturing / Lean Manufacturing

• Preventing problems

• Detecting problems: Statistical Process Control

• Analyze the root cause of problems

• Qualitative Six Sigma Tools

Schedule and Classroom:

• Online

Examinations and Grading Criteria (Subject to change):

• Assignments: 30% - Announced throughout the semester

• Midterm Exam: 35%

• Final Exam 35% - To be explained in detail during the course

Bonus points will be credited throughout the course.

The grading is subject to change and the changes will be communicated with the students.

Textbook:

1. Introduction to Statistical Quality Control, by D. C. Montgomery, 7th edition 2012, Wiley, ISBN-10: 1118146816, ISBN-13: 978-1118146811, (Earlier versions are also acceptable).

2. Additional handouts may be providing during the semester.

Recommended (Optional) Reading:

1. Probability and Statistics for Engineers and Scientists – Sixth Edition by Walpole, Myers and Myers, 1998, ISBN: 0-13-840208-6.

2. Statistics for Six Sigma Made Easy !

3. Statistical Quality Control, by E.L. Grant and R.S. Leavenworth, 6th edition, McGraw-

Hill, ISBN: 0078443547.

Software:

General spreadsheet applications will be used throughout the semester.

Policies:

• Late homework / project assignment submission will not be accepted.

• Three or more unexcused absences will result in an automatic failure.

• Make-up exams / quizzes will not be allowed (except for prior instructor approval for a documented emergency)

• Homework assignments and programs are due within a week from the assignment date, unless the instructor notes otherwise.

• All homework assignments are to be typed.

• All programs are to include sufficient comments and documentation with a clear program statement.

• Extra credit quizzes, assignments, and programs (if any) will be announced by the instructor.

• It is the student's responsibility to familiarize himself or herself with and adhere to the standards set forth in the policies on cheating and plagiarism as defined in Chapters 2 and 5 of the Key to UB or the appropriate graduate program handbook.

• As a UB policy, it is expected that each student that attends one hour of classroom instruction will require a minimum of two hours of out of class student work each week for approximately fifteen weeks for one semester.

Assignment Submission Guidelines

1. Computer-type your assignments (preferably MS-Word format).

2. Save your file with a proper filename format:

e.g: If the student name is Elif Kongar, student ID# 0123456, Homework Assignment 1; the filename should be:

TCMG524DL_Elif_Kongar_0123456_HW1.

3. Login to myub and click on the Canvas link under Library & Technology Resources. Use the first part of your UB email as username (for example: jbond, without the @bridgeport.edu) and follow the instructions to set up your password.

4. Sign in to your UB Canvas account and then into the course, e.g. “Statistical Quality Control Techniques” to submit your assignments.

To access Canvas tutorial for faculty:



UB Canvas account can also be accessed through the URL:



Low-stakes* Assignment

*Low-stakes assignments are forms of evaluation that do not heavily impact students’ final grades. For this course, low-stakes are designed specifically to encourage students to work on additional topics.

The filename for low-stakes assignments should follow the format provided below:

TCMG524DL_Elif_Kongar_0123456_LS_HW1.

Useful Links for TCMG 524 DL Fall 2016 Assignments

How to draw a box plot in Excel?



How to create histogram in Excel?



Quartiles of normal distribution



Interquartile range



Using Z table and Excel to calculate different probabilities

P ( Xa),P(X=a)



How to create a Pareto chart in Excel



How to create Pareto chart in Excel



How to create fishbone template on excel



X bar and R charts



X bar and R charts on Excel



ARL part1



ARL part2



Important Dates

Classes Begin Monday, 8/29

Midterm Exam Tuesday, 11/1

Thanksgiving Recess – No Classes Wednesday-Sunday, 11/23 – 11/27

Final Exam Tuesday, 11/29

Last Day of Classes Friday, 12/9

Final Grades Due Monday, 12/19

Academic Calendar:



Grading scale

|Letter Grade |Percentage |

|A |94.9 – 100% |

|A- |90 – 94.8% |

|B+ |87 – 89.9% |

|B |83 – 86.9% |

|B- |80 – 82.9% |

|C+ |77 – 79.9% |

|C |73 – 76.9% |

|C- |70 – 72.9% |

|D+ |67 – 69.9% |

|D |63 – 66.9% |

|D- |60 – 62.9% |

|F |Below 60% |

Weekly Schedule (8/29/16 12/9/16)

Please note that the class notes and handouts are updated every week

General Instructions (Posted before classes start)

• Canvas Student Tutorial - Overview.docx

• Instructions for Journal Article and E-book Search.doc

• Welcome Note

|Week |Date |Topic |

|1 |8/30 |Syllabus / Introduction to the Class |

| | |(Welcome Note and Instructions) |

| | |Data Representation (ppt) |

|2 |9/6 |Lecture 1: Statistics Overview |

| | |Odds and Probability |

| | |Descriptive Statistics: Average, Mode, Mean, Standard deviation |

| | |Inferential Statistics |

| | |Plotting Data: Histogram, Stem and Leaf Plot |

| | |Normal Distribution Properties |

| | |Additional Files: TCMG 524 DL - Homework Aid – Assignment 1 |

| | |Supplementary Materials: Histogram-template (xls) |

| | |Pareto-template |

| | |Stem-and-leaf-template |

| | |Assignment 1: Excel Applications |

|3 |9/13 |Lecture 2 |

| | |Regression Review |

| | |History of Quality Improvement |

| | |Statistical Methods for Quality Improvement |

| | |Introduction to Six Sigma |

| | |X-bar Chart Example |

| | |DMAIC |

| | |Supplementary Materials: Simple Linear Regression (ppt + xls) |

| | |Z Table - Area between 0 and z (doc) |

| | |Cumulative_Negative_z_table (pdf) |

| | |Additional Files: TCMG 524 DL - Homework Aid – Assignment 2 |

| | |Assignment 1 is due |

| | |Low-stakes* Assignment 1: Regression Analysis |

| | |Assignment 2: Reading the z-table/randomness |

|4 |9/20 |Recent Reading Materials: Week 4 Reading and Videos |

| | |Reading: Benefits, obstacles, and future of six sigma approach |

| | |Video: Data representations, population, demographics |

| | |Video: Six Sigma Basics, MIT OpenCourseWare |

| | |Low-stakes* Assignment 1 is due |

| | |Discussion forum starts: Case Study I |

|5 |9/27 |Lecture 3: Magnificent Seven |

| | |Histogram or stem-and-leaf plot |

| | |Check sheet |

| | |Pareto chart |

| | |Cause-and-effect diagram (Ishikawa/Fishbone) |

| | |Defect concentration diagram |

| | |Scatter diagram |

| | |Intro to Control charts |

| | |Supplementary Materials: Check-sheet-histogram (xls) |

| | |Check-sheet-template-2 (doc) |

| | |Stratification (pdf) |

| | |Stratification-diagram-template (xls) |

| | |Fishbone-template |

| | |Additional Files: Visio Instructions |

| | |Assignment 2 is due |

| | |Assignment 3: Magnificent seven |

|6 |10/4 |Lecture 4 |

| | |Flow charts |

| | |Control Charts |

| | |Assignment 4: Control charts |

| | |Low-stakes* Assignment 2 – Fishbone |

| | |Assignment 3 is due |

|7 |10/11 |Lecture 5 |

| | |The Box Plot |

| | |Average Run Length (ARL) |

| | |Type I and Type II Error |

| | |Probability calculations using normal distribution properties |

| | |Assignment 4 is due |

| | |Assignment 5: Box-plot/ARL/Calculations |

| | |Additional Files: TCMG 524 DL - Homework Aid – Assignment 5 |

| | |Supplementary Materials: Excel_2007_Box_Plot_Workbook (xls) |

| | |Box-plot-template (xls) |

|8 |10/18 |Lecture 6 |

| | |Normal Probability Plot |

| | |Other Probability Plots |

| | |Process Capability |

| | |Phase I and Phase II – Quality Control Charts |

| | |Low-stakes* Assignment 2 is due |

| | |Assignment 5 is due |

| | |Assignment 6: Probability plot/Process capability/Phase I and II Calculations |

| | |Additional Files: TCMG 524 DL - Homework Aid – Assignment 6 |

| | |Supplementary Materials: Process Capability-Additional (pdf) |

|9 |10/25 |Prepare for the Midterm Exam (Previous Midterm Exams are posted) |

|10 |11/1 |Midterm Exam |

|11 |11/8 |Lecture 8 |

| | |Midterm Exam Solutions |

| | |Discussion forum starts: Case Study II |

| | |Midterm Exam is due |

|12 |11/15 |Lecture 9 |

| | |More on Quality Control Charts: Which one to use and when? |

| | |Phase I and Phase II QC Charts Detailed |

|13 |11/22 |Lecture 10 |

| | |Improvement Case Study: Mega Bytes Restaurant |

| | |Seven Step Methodology |

|14 |11/29 |Final Exam |

|15 |12/6 |Final Exam is due |

| | |Lecture 11 |

| | |Final Exam Solutions |

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