1. Ian Davison
Linda Donoghue
David Fransman
Noah Zenker

2. Introduction
Critical to all aspects of manufacturing, from design
to packaging and beyond
Quality Standards
Statistical Process Control
Quality Inspection Equipment
Failure Testing

3. Linda Donoghue

4. Six Sigma
Developed by the Motorola Company
Method of improving quality by reducing variability in
products and processes
Data driven decision making
Defined by the statistical levels expected for compliance
 standard deviation of less than six sigma from the mean to the
most extreme specification limits
Requires high precision and repeatability
Only 3.4 defects per million allowed
Results in fewer defects, lower costs, greater customer
voice

5. Figure 36-19 DeGarmo's Materials & Processes in Manufacturing

6. Lean Manufacturing
Maximize efficiency while minimizing waste
Desires continuous operation with 100% parts
First-time quality
In-process quality checks
Planning
Pin points priority areas of quality consideration

7. ISO Standards
International Organization for
Standardization
Main purpose is to create internationally agreed upon
standards
Less variability
Greater promotion of worldwide competition
Voluntary, but highly regarded standards

8. ANSI Standards
American National Standards Institute
National standards which help meet the
internationally declared ISO standards
Valuable for market acceptance
Unlike ISO, ANSI does not create the standards, only
supervises the development and use of standards

9. ISO and ANSI in Manufacturing
Often set the bar for government regulations
Operator qualifications
Dimensioning and tolerances
Acceptable use of machinery and tools
Requirements for automation software, coding,
symbols, and terminology
Safety and testing requirements
Material handling requirements

10. GMP
Good Manufacturing Practice
Guidelines for manufacturing processes that affect
quality in
Food production
Medical devices
Pharmaceuticals
Lawfully enforced by the FDA
Includes batch records, distribution tracking, testing,
operator training, etc.

11. Noah Zenker

12. What is Statistical Process Control?
Constant in-process sampling of a production
variables
 Data points are compared to average (Control chart)
 Problems isolated
 Modifications made to flagged area(s)
 Repeat
 Never ends while product still being produced

13. Statistical Process Control – Graphical Representation

14. Benefits of SPC
 Provides a method of surveillance and feedback for keeping processes
in control
 Signals when a problem with the process has begun and is about to
affect quality adversely
 Detects assignable causes of variation or root causes
 Reduces the need for inspection due to predictability
 Monitors process quality at the source
 Provides a mechanism to make process changes and track the effects
of those changes
 Once causes of variation have been eliminated, SPC provides ongoing
process capability analysis with comparison to the desired outcome

15. Requirements for SPC
Processes being considered for SPC must:
 Be well defined
 Have attributes with observable measures
 Be repetitive
Be sufficiently critical to justify monitoring

16. SPC Implementation Pitfalls
Measurement variability
 The process of measuring must be uniform throughout the
process.
 Incorrect goals for SPC
 Control charts should be constructed so as to detect process
trends rather than individual nonconforming events
 Poor follow-up
 SPC only signals the possible existence of a problem.
 Without detailed investigations, as in an audit, and
instituting corrective action, SPC will not provide any
benefit.

17. Example of SPC in action
 Statistical Process Control used by Raytheon
 Wanted to monitor solder defects in surface mount assembly (Insufficient or excess
solder)
 Raytheon used SPC to constantly monitor the soldering application
 Solder screen condition
 Solder screen tension
 Squeegee pressure
 Squeegee speed
 Solder past viscosity
 Solder paste particle size
 SPC gave Raytheon:
 Improved process capability
 Higher quality
 Increased yield in surface mount assembly

18. SPC Conclusion
SPC significantly improves profit and adds value by:
Improving product and service quality
Improving productivity
Streamlining processes
Reducing waste
Reducing environmental emissions
Improving capacity and predictive outcomes

19. Ian Davison

20. Quality Inspection Methods
There are two main ways to inspect the quality of a
part for dimensional accuracy and quality
specifications.
Tactile: Using an instrument that comes in contact
with the part to measure and quantify aspects of a
part or component.
Visual: Using an instrument that does not come in
contact with the part, but uses visual methods of
comparison to quantify aspects of a part or
component.

21. Quality Inspection Equipment
There are two main categories of quality inspection
equipment.
Gauges: a piece of equipment designed specifically to
measure a single part or component.
Metrology Equipment: A piece of equipment versatile
enough to measure a wide range of parts, typically
requiring a custom fixture to hold each part.

22. Single Purpose Inspection Gauges
There are two kinds of gauges: Go/No Go Gauges, and
Variable Measurement Gauges.
Go/No Go example: Testing the size of a .125” pin with a
bilateral .005” tolerance. If the Pin fits through a hole of
size .130” without jamming and does not fit through a hole
of size .1245”, the pin will pass a Go/No Go quality
inspection. If the pin does not fit through the .130” hole or
slips through a .1245” hole, the pin will not pass a Go/No
Go quality Inspection.
A Variable Measurement Gauge would be a measurement
instrument designed to measure one type of part but be
able to output a wide range of measurements. These kinds
of gauges can also be used to monitor the manufacturing
process and catalog trends of certain aspects or
dimensions of a particular part.

23. Indicators – The Most Basic Tactile
Inspection Instrument
•Dial indicators and digital drop indicators are the most basic form of tactile measurement
instrumentation second to a ruler, calipers, and micrometers used for dimensional inspection
and would fall into the metrology equipment category. Indicators can be used on their own
mounted to a versatile stand, or incorporated permanently into a single purpose gauge.
•Dial indicators can measure parts with an accuracy between .001” and .005” depending on the
unit.
•Digital drop indicators can measure down to 0.00005” accurately (arguable).

24. Variable Measurement Gauge
Above is an example of a fixture for a variable measurement gauge. The part
would be clamped by the De-Sta-Co clamp and put under a drop indicator.
The indicator would be zeroed on the surface that the pins come out of
(Datum Surface) and then the probe would be lifted and placed on the part
surface. The measurement would be recorded.

25. Go / No Go Gauge
 Above is an example of a Go / No Go Gauge. This particular gauge was used to
ensure the slot width of a not yet released part was within specification. The
Go shim of this gauge has a thickness of .012”, the No Go shim of this gauge
has a thickness of .01335”. Both shims were made with a Wire EDM. The shims
were verified with a drop indicator, a toolmakers microscope, and an optical
comparitor. The latter two of which will be detailed later in this presentation.

26. Coordinate Measurement Machine
(CMM)
 The CMM is typically a CNC
machine that uses a tactile probe to
trace the profile of a part and
measure particular internal and
external features.
 The CMM works in 3 dimensions and
the X and Y axes typically ride on a
compressed air buffer.
 CMM’s can also use visual, laser,
white light, or air cushion touchless
probes.
 Some of the best CMM’s have a
resolution of 0.000004”.
 The CMM is one of the most precise
pieces of tactile quality inspection
equipment.

27. Visual Inspection Equipment
There are three types of visual inspection equipment:
Optical Comparators (also known as a shadow graph)
Toolmakers Microscope
CNC Optical measurement instruments

28. Optical Comparator
 An Optical Comparator is a
measurement device with an XY table,
a stage, a light source, various lenses,
and a projection screen.
 The light is shone on a part placed in
a fixture on a the stage, the shadow is
cast into the lens, the shadow is then
reflected through mirrors and cast
onto the screen.
 The screen has graduations on it and
an origin.
 Typically a quality inspector would
zero the XY read-out with the origin
placed on a feature, the table jogged
until the origin lies on the desired
feature to be measured, and the
measurement recorded from the readout.

29. Tool Makers Microscope
A tool makers mic is a more
direct version of a comparator.
There is a combination of top
and back stage lighting and a set
of crosshairs in the microscope
eye piece.
Typically there is a digital readout integrated with the stage.
The crosshairs are zeroed on the
edge of a part, the stage jogged
until the crosshairs are at the
other edge of the desired
feature, and a measurement
taken from the read-out.

30. CNC Visual Measurement Systems
Highly advanced optical
measurement systems
using both lasers and
digital imaging in
conjunction with software
able to recognize and
measure features from
images taken by the
machine.
Multiple features can be
measured in one run.
Measurement accuracy
down to a few microns.

31. David Fransman

32. Failure Testing
Failure testing: a way of ensuring a product will not
fail under different circumstances and situations of
stress, weather, temperature, and etc.
Testing allows an engineer to match up their
predictions to real life applications.
The results will help the designer rethink the product
and make necessary changes to meet the customers
needs.
Since quality control ensures a product meets
customer needs, testing can be considered a way to
influence product quality.

33. Failure Testing Methods
Tensile testing
Determines how a material
reacts to the applied tensile
forces.
You can find ultimate tensile
strength, modulus of rigidity
and stain.
Inexpensive after initial
investment
Simple to implement.
Images.google.com

34. Failure Testing Methods Cont.
Wear testing
Determines the effects of
continuous contact between two
surfaces.
 You can find the friction factor
and amount of wear to a
surface.
Simple to implement
Inexpensive after initial
investment is made.
Images.google.com

35. Failure Testing Methods Cont.
Chemical Resistance Test
Determines the ability of a
material to resist changes in
its physical properties when
exposed to certain
chemicals.
You can find the rate at
which a chemical reacts a
product.
Testing with certain
chemical can be dangerous.
Images.google.com

36. Failure Testing Methods Cont.
Fatigue Testing
Determines the number of times
an object is able to withstand
before failing.
You can determine how long it
takes the product to fail.
Testing machines are used to
apply cyclic loads so you can
easily model test to mimic a real
life cycle pattern.
Images.google.com

37. Failure Testing Methods Cont.
Testing at the extremes.
Test done beyond the normal
operation conditions of a
product.
You can determine the time it
takes to fail.
You can also detect unsafe
failure at these certain
conditions.
Images.google.com

38. Failure Testing Defines Quality
Performance
Does the product withstand the customers operating
conditions?
Longevity
Does the life of the product be what your customer
wants?
Safety
When a product fails could it potentially cause harm to
the customer?

39. Conclusion
Quality Systems in Manufacturing
Quality Standards
Statistical Process Control
Quality Inspection Equipment
Failure Testing
Questions ? ? ?