Curriculum Map

Course: Quality Control

Description
This curriculum map provides a mapping of content from Juran's Quality Handbook, The Six Sigma Handbook and Statistical Process Control Demystified to standard Quality Control course topics.  The author carefully selected relevant examples, videos, tables and figures which he felt would be valuable supplements to any standard Quality Control textbook. You can easily incorporate the content into your course by using our copy link functionality to paste a direct link into your school's LMS.

Author
Craig G. Downing, Ph.D., CMfgE, Department Head and Associate Professor of Engineering Management, Rose-Hulman Institute of Technology

Course Topics

• Control Charts
• Process Capability
• Statistical Tools
• Designed Experiments
• Measurement Systems Analysis




Control Charts

Relevant Material	Type	Description	Source
Table 18.1 Variation Categorization	Table	Distinctions between random and assignable causes of variation	Juran's Quality Handbook
Figure 2.6 Control Chart Selection	Figure	SPC selection diagram	Statistical Process Control Demystified
Figure 18.24 X-bar/R Chart Example	Figure	Example of variable control charting	Juran's Quality Handbook
Chapter 5: Charts	Text	Explains the construction, use and interpretation of x-bar, range and sigma charts	Statistical Process Control Demystified
Table 5.1 X-bar/S Chart Data	Table	Table with example data from a manufacturing process	Statistical Process Control Demystified
Figure 5.2 X-bar/S Chart Example	Figure	Example x-bar/sigma chart based on Table 5.1 data	Statistical Process Control Demystified
Chapter 5 Quiz	Quiz	Multiple choice questions on control charts	Statistical Process Control Demystified
Chapter 4: Attribute Control Charts	Text	Descriptions and examples of attribute control charts	Statistical Process Control Demystified
Table 4.1 Attribute Data	Table	Example of order processing attribute data	Statistical Process Control Demystified
Figure 4.1 P Chart	Figure	Example p chart of percent of orders with errors from data in Table 4.1	Statistical Process Control Demystified
Figure 4.2 Np Chart	Figure	Example Np chart of number of orders with errors in 100-order sample from data in Table 4.1	Statistical Process Control Demystified
Figure 4.3 U Chart	Figure	Example u chart of errors per order from data in Table 4.1	Statistical Process Control Demystified
Figure 4.4 C Chart	Figure	Example c chart of errors per order in the 100-order sample from data in Table 4.1	Statistical Process Control Demystified
Still Struggling?	Text	To determine which chart to use consider the type of data being collected	Statistical Process Control Demystified
Chapter 4 Quiz	Quiz	Multiple choice questions on attribute control charts	Statistical Process Control Demystified
Chapter 8: Process Behavior Charts	Text	Explanation of using control charts within statistical process control (SPC)	The Six Sigma Handbook
Construction and Interpretation of X-Bar Control Charts	Video	Discusses basic construction and interpretation of the X-bar control chart	The Six Sigma Handbook
XBar Control Chart Calculations	Video	Reviews calculations used to construct X-bar/Range and X-bar/Sigma control charts	The Six Sigma Handbook
Control Chart Interpretation: Historical Data	Video	Demonstrates use of the x-bar control chart for a retrospective analysis of historical data	The Six Sigma Handbook
Control Chart Interpretation: Multiple Stream Processes	Video	Discusses rational subgrouping and demonstrates the effect of an irrational subgroup obtained from multiple process streams on the x-bar control chart; also use of batch means chart as a remedy	The Six Sigma Handbook
Control Chart Interpretation: Autocorrelation	Video	Discusses rational subgrouping and demonstrates the effect of an irrational subgroup due to process autocorrelation on the x-bar control chart; also use of batch means chart as a remedy	The Six Sigma Handbook
Control Chart Interpretation: Data Resolution	Video	Demonstrates the effect of insufficient data (i.e. measurement) resolution on the x-bar control chart	The Six Sigma Handbook
Constructing X-Bar Control Chart in Minitab	Video	Demonstrates the construction of the x-bar control chart within Minitab	The Six Sigma Handbook
Analyzing Individuals Data on Process Control Charts	Video	Demonstrates analysis of individuals (n=1) data when process distribution is unknown; shows use of moving average and EWMA control charts to determine process stability prior to fitting a distribution for use on an individuals chart or in process capability	The Six Sigma Handbook
Effect of Mutli-stream Processes on Attribute Control Charts	Video	Discusses rational subgrouping and demonstrates the effect of an irrational subgroup obtained from multiple process streams on the p chart	The Six Sigma Handbook
Figure 23.2 Template for Use in Special Cause Analysis	Figure	Example template that applies the Plan-Do-Study-Act (PDSA) cycle	Juran's Quality Handbook
Figure 18.25 Special Out of Control patterns	Figure	Eight tests for special causes applied to control charts using 3 sigma limits	Juran's Quality Handbook

Process Capability

Relevant Material	Type	Description	Source
Section 19.11: Process Capability	Text	Explanation of process capability	Juran's Quality Handbook
Figure 19.30 Cp Illustrations	Figure	Four examples of process variability	Juran's Quality Handbook
Chapter 3: Determining Suitability to Requirements	Text	Explanation of process capability	Statistical Process Control Demystified
Table 3.1 Error Rate for Cpl, Cpu	Table	Conversion between a given Cpk value and an error rate, expressed in percent	Statistical Process Control Demystified
Figure 3-1 A & B Cp and Cpk Illustrations	Figure	Distribution curves illustrating processes centered within specifications and processes not centered within specifications	Statistical Process Control Demystified
Chapter 3 Quiz	Quiz	Multiple choice questions on process capability	Statistical Process Control Demystified
Process Capability in Minitab	Video	This video demonstrates the construction and intrerpretation of a Process Capability Analysis within Minitab, when a Normal Distribution may be assumed.	The Six Sigma Handbook

Statistical Tools

Relevant Material	Type	Description	Source
Figure 18.8 Fishbone (Cause & Effect) Diagram	Figure	Example of a cause-effect diagram	Juran's Quality Handbook
Figure 19.13 Hypothesis Test Selection	Figure	Roadmap to assist in deciding what hypothesis test(s) are appropriate	Juran's Quality Handbook
Figure 2.4 Pareto Diagram	Figure	Pareto diagram of issue types for phone support example	Statistical Process Control Demystified
Section 7.4: Regression Analysis	Text	Explanation of regression analysis	Statistical Process Control Demystified
Table 7.1 Regression Data	Table	Order processing time data based on number of line items per order	Statistical Process Control Demystified
Figure 7.5 Scatterplot Diagram	Figure	Scatter diagram of Table 7.1 data	Statistical Process Control Demystified
Chapter 7 Quiz	Quiz	Multiple choice questions on process improvement	Statistical Process Control Demystified
Section 10.3: Regression and Correlation Analysis	Text	Explanation of regression and correlation analysis	The Six Sigma Handbook
Regression Analysis in Minitab	Video	This video demonstrates the construction and interpretation of a regression analysis within Minitab.	The Six Sigma Handbook
Scatter Diagrams in Minitab	Video	This video demonstrates the construction and interpretation of a scatter diagram within Minitab. The example is continued using stratification to investigate possible effects of an additional factor.	The Six Sigma Handbook

Designed Experiments

Relevant Material	Type	Description	Source
Section 19.8.7: Design of Experiments	Text	Explanation of designed experiments, including a contrast with classical methods of experimentation	Juran's Quality Handbook
Table 19.11 Comparison of Classical and Modern Methods of Experimentation	Table		Juran's Quality Handbook
Table 19.12 Classification/Application of Designs	Table	Lists types of applications for which different types of designs are appropriate	Juran's Quality Handbook
Section 7.7: Designed Experiments	Text	Explanation of designed experiments	Statistical Process Control Demystified
Table 7.5 Factorial Design Data	Table	Experimental design template with example data	Statistical Process Control Demystified
Figure 7.8 Factorial Design Analysis	Figure	Initial analysis results of Table 7.5 experimental results	Statistical Process Control Demystified
Figure 7.9 Factorial Design Analysis - Cleaned Up	Figure	Resulting analysis of Table 7.5 data (after removing insignificant terms)	Statistical Process Control Demystified
Chapter 7 Quiz	Quiz	Multiple choice questions on process improvement	Statistical Process Control Demystified
Section 10.4: Designed Experiments	Text	Explanation of the role of designed experiments in quality improvement	The Six Sigma Handbook
Design of Experiments in Minitab: Generating the Design	Video	This video demonstrates the construction and interpretation of a regression analysis within Minitab.	The Six Sigma Handbook
Design of Experiments: Analysis of Data within Minitab	Video	This video demonstrates the construction and interpretation of a scatter diagram within Minitab. The example is continued using stratification to investigate possible effects of an additional factor.	The Six Sigma Handbook
Analyzing a Designed Experiment in MS Excel-Part 1	Video	This video demonstrates the initial interpretation of a Screening Design data within MS Excel, using data generated by the IQF Lean Six Sigma Black Belt Certification Exam.	The Six Sigma Handbook
Analyzing a Designed Experiment in MS Excel-Part 2	Video	This video demonstrates the interpretation of the expanded Screening Design data (with interactions) within MS Excel, using data generated by the IQF Lean Six Sigma Black Belt Certification Exam.	The Six Sigma Handbook

Measurement Systems Analysis

Relevant Material	Type	Description	Source
Section 19.6.5: Measurement System Analysis	Text	Attributes of a good measurement system	Juran's Quality Handbook
Figure 19.3 Sources of measurement variation	Figure	Five sources of measurement variation	Juran's Quality Handbook
Figure 19.6 – 19.10 MSA example	Example	Measurement System Analysis Example	Juran's Quality Handbook
Section 8.5: Repeatability and Reproducibility (R&R)	Text	Explanation of repeatability and reproducibility (R&R) errors	Statistical Process Control Demystified
Table 8.2 R&R data	Table	Example R&R data	Statistical Process Control Demystified
Figure 8.3 Repeatability control chart example	Figure	Repeatability control chart for Table 8.2 data	Statistical Process Control Demystified
Figure 8.4 Reproducibility Control Chart Example	Figure	Reproducibility control chart for Table 8.2 data	Statistical Process Control Demystified
Chapter 8 Quiz	Quiz	Multiple choice questions on Measurement Systems Analysis	Statistical Process Control Demystified
Reproducibility Example	Example	Alternative method for evaluating reproducibility error that provides control chart	The Six Sigma Handbook
Table 9.2 Measurement Error data for Reproducibility Evaluation	Table	Example data for alternative method for evaluating reproducibility error	The Six Sigma Handbook
Section 9.2: Example of Measurement System Analysis Summary	Example		The Six Sigma Handbook
Measurement Systems Repeatability & Reproducibility (R&R) Analysis	Video	This video demonstrates the R&R analysis of a measurement system, using the classical Average Range technique with control charts for Repeatability and Reproducibility.	The Six Sigma Handbook
Measurement Systems R&R Analysis using ANOVA	Video	This video demonstrates the ANOVA method of R&R analysis using Minitab.	The Six Sigma Handbook