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What is INSE 6220?

INSE 6220 -- Week 1

Advanced Statistical Approaches to Quality

INSE 6220 is a Quality Systems Engineering course

Go over Course Outline

You will learn

Overview of Quality Control

Introduction to Statistical Quality Control

To apply control charts to monitor the quality characteristics of a product or

process
Learn techniques for multivariate process monitoring and diagnosis
Design and analyze experiments for improving a manufacturing process
Learn how to determine the reliability of engineering systems

You do not need prior knowledge of MATLAB programming

but previous experience with programming is a must
Dr. A. Ben Hamza

Concordia University

Instructor: Dr. A. Ben Hamza

Roadmap of the Course?

INSE 6220

Office:

EV 7.631

Lectures:

Friday

17:45 - 20:15

Statistical
Process Control

Process Quality

Office Hours:

Wednesday 14:00 - 16:00 or by appointment

E-Mail:

hamza@ciise.concordia.ca

Modeling

Inferences

Statistical
Methods

Control Charts

Capability
Analysis

Midterm Exam

Engineering
Process Control

Experimental
Design

Multivariate

Acceptance
Sampling

Final Exam

Administration
Course web page:

What this course is about?

This course is about Advanced Statistical Techniques for Quality

MyConcordia Portal (Moodle)

Its highly advised to check Moodle regularly.

Control Engineering

Syllabus, Slides, Assignments, Projects, etc

Objectives:

Go to MyConcordia Portal (Moodle).

To learn the fundamental concepts of Quality Control

To learn how to apply control charts to monitor the quality

Preliminary exam dates and project due date:

Midterm Exam
October 17, 2014 (Friday)

Project due
December 2, 2014
Final Exam
December ??, 2014 (TBA)

characteristics of a product or process

To learn techniques for multivariate monitoring and diagnosis
To design and analyze experiments for improving a manufacturing
process
To learn how to determine the reliability of engineering systems

Grading Policy

What is this course really about?

Important Dates:

Two Assignments

10%

Midterm Exam

30%

Project

15%

Final Exam

45%

Oct 10, 2014:

Oct 17, 2013:
Nov 28, 2014:
Dec 2, 2014:
Dec ??, 2014:

Assignment #1 due
Midterm Exam
Assignment #2 due
Project Report due
Final Exam

Final Project

Final reports due on December 2, 2014

A final project report, completed individually or in teams of two, is required.
The term project will have only one component: written report.
For more details: MyConcordia Portal (Moodle)

We will cover...

Statistical Process Control (SPC)

Control Charts
Process and Measurement System Capability Analysis
Multivariate Process Monitoring and Control
Engineering Process Monitoring and Control
Process Design
Acceptance Sampling
And much more

What is statistics?
The science of collecting, organizing, analyzing, and interpreting data in

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Quality
General Understanding:

order to make decisions.

Methods for processing and analyzing numbers
Methods for helping reduce the uncertainty inherent in decision making

Desirable characteristics that a product

or service should possess.

Why Learn Statistics?

So you are able to make better sense of the ubiquitous use of numbers:

Business memos
Software defect data
Quality control
Data mining
Quality assurance

The Eternal Battle:

Quantity vs. Quality
Quantity goes directly to the bottom
line:
more product out ==> more $$$

But what are the costs associated

with Quality?

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What is Statistics?

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What is Quality?

1.

Collecting Data
e.g., Survey

2.

Data
Analysis

What makes a good quality

Why?

Presenting Data

car
computer
knife
childrens toy
pizza delivery

e.g., Charts, Graphs & Tables

3.

DecisionMaking

Characterizing Data

Describe a recent time when you

have experienced bad quality?

So what are the common aspects of

quality?

e.g., Average

1984-1994 T/Maker Co.

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What is Quality?

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Expressing Dissatisfaction

Fitness for Use

Conformance to Specifications
Producing the Very Best Products
Excellence in Products and Services
Total Customer Satisfaction
Exceeding Customer Expectations

Public action
can be
Takes
action
A dissatisfied
customer

Seeking redress directly from

the firm
Taking legal action
A complaint to business, private,
or governmental agencies

Private action

Quality improvement starts with reducing Product VARIABILITY.

Stop buying the product or

boycott the seller

Takes
no action

Warn friends about the product

and/or seller

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Quality - Whats the Big Deal?

Eight Dimensions of Quality

Direct Costs of Poor Quality:

1. Performance: Will the product do the intended job?

2. Reliability: How often does the product fail?
3. Durability: How long does the product last?
4. Serviceability: How easy is it to repair the product?
5. Aesthetics: What does the product look like?
6. (Added) Features: What does the product do?
7. Perceived Quality: What is the reputation of the company or its

Lost Revenue: scrap, rework, repair

Lost Productivity: materials, machines, and personnel
Inspection Costs: inspectors, testing machines
External Costs: warranty claims, price adjustments, late charges

Indirect Costs of Poor Quality - Upset Customers:

It is 5-7X harder to attract a new customer than to retain a current one
Dissatisfied customers tell 8-20 people about their dissatisfaction.
Satisfied customers only tell 3-5 people.

8.

product?
Conformance to Standards: Is the product made exactly as the
designer intended?

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Quality Improvement

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Key Definitions in Statistics

Improve quality
Quality is better if variability in the important quality characteristics of a product
decreases.
Quality improvement is the reduction of variability in processes and products.

Quality characteristics
Types
Physical: Length, weight, volume, viscosity,
Sensory: taste, appearance, color,
Time orientation: reliability, durability, serviceability,

Data are needed to characterize quality characteristics

Data can be classified

A population (universe) is the collection of things under

consideration

A sample is a portion of the population selected for

analysis

A parameter is a summary measure computed to

describe a characteristic of the population

A statistic is a summary measure computed to describe a

characteristic of the sample

Attributes discrete
Variables continuous

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Quality Engineering

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Population and Sample

The operational, managerial, and engineering activities that a company uses to ensure
that the quality characteristics of a product are at the nominal or required levels.
We dont want variability from the nominal levels.
Statistical methods are used to deal with variability
Control Charts; Acceptance Sampling; Design of Experiments
Quality Management System

Total Quality Management

Six Sigma: data-driven methodology for eliminating defects
Control Charts
DOE (Design of Experiments)
QFD (Quality Function Deployment)

Six Sigma processes are executed by Six Sigma Green Belts and Six
Sigma Black Belts, who are overseen by Six Sigma Master Black Belts.
To achieve Six Sigma, a process must not produce more than 3.4 defects per
million opportunities.
A Six Sigma defect is defined as anything outside of customer specifications.

Population

Sample
Use statistics to
summarize features

Use parameters to
summarize features

Inference on the population from the sample

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SPC/Control Chart

Why a Manager Needs to

Know about Statistics

To know how to properly present information -

KNOWLEDGE

To know how to draw conclusions about populations

Control charts
Useful in monitoring processes,
On-line technique
Walter A. Shewart (1891-1967)
Bell Labs, developed the first control chart about 1924

based on sample information

To know how to improve processes- IF YOU DONT

KNOW WHATS GOING ON, YOU CAN NEVER
IMPROVE A PROCESS

Statistical Process Control

new important tool: control chart

measurements of production process
during production
prevention instead of detection afterwards
monitoring variance behaviour of
production
corresponding definition of quality:
variation of process fits within
tolerances
How do we reduce Product Variability?
We use Statistical Process Control ! (SPC)
Statistical Process Control:
The application of statistical techniques to
the control and improvement of processes.

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Design of Experiments
Discovering the key factors that influence process performance
Process optimization
Off-line technique

A factorial experiment with three factors

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Six Sigma

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Companies implementing Six Sigma

Use of statistics & other analytical tools has grown steadily for over 93 years
Statistical quality control (origins in 1920, explosive growth during WW II,
1950s)
Operations research (1940s)
TQM (Total Quality Management) movement in the 1980s
Reengineering of business processes (late 1980s)
Six-Sigma (origins at Motorola in 1987, expanded impact during 1990s to
present)
Six Sigma focus on Process Improvement with an Emphasis on Achieving
Significant Business Impact
A highly structured strategy for acquiring, assessing, and applying customer,
competitor, and enterprise intelligence for the purposes of product, system or
enterprise innovation and design.
To achieve Six Sigma, a process must not produce more than 3.4 defects per 1
million opportunities. A Six Sigma defect is defined as anything outside
customer specifications.

Motorola

Texas Instruments
ABB
AlliedSignal
GE
Bombardier
Nokia

DuPont
American Express
BBA
Ford
Dow Chemical
Johnson Controls
Noranda
Toshiba

3.4 defects per million opportunities (DPMO)

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Six Sigma TrainingBlack Belt Program

Six Sigma
The fundamental objective of the Six Sigma methodology is the implementation
of a measurement based strategy that focuses on process improvement and
variation reduction. This is accomplished through the use of DMAIC
(Define, D
Measure,
efine Analyze, Improve, Control)

Define
Measure

Define the problem and customer

requirements.

Measure defect rates and document

the process in its current incarnation.

Control

Measure Analyze process data and determine

the capability of the process.

Improve the process and remove

defect causes.

Improve

Analyze

Control process performance and

ensure that defects do not recur.

Improve

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Analyze

Session One
Understanding Six Sigma
Developing the Language of Six Sigma and Statistics
How to Compute and Apply Basic Statistics
How to Establish and Benchmark Process Capability
Session Two
Understanding the Theory of Sampling and Hypothesis Testing
How to Apply the Key Statistical Tools for Testing Hypotheses
Understanding the Elements of Successful Applications Planning
How to Apply and Manage the Breakthrough Strategy
How to Identify and Leverage Dominant Sources of Variation
How to Establish Realistic Performance Tolerances
Session Three
Understanding the Basic Principle of Experimentation
How to Design and Execute Multivariable Experiments
How to Interpret and Communicate the Results of an Experiment
How to Plan and Execute a Variable Search Study
Session Four
Understanding the Basic Concepts of Process Control
How to Construct, Use, and Maintain Charts for Variables Data
How to Construct, Use, and Maintain Charts for Attribute Data
How to Implement and Maintain Pre-control and Post-control Plans
How to Plan and Implement Process Control Systems

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MATLAB Desktop

How to start and quit MATLAB?

PC - a double click on the MATLAB icon on

your desktop

Launch Pad

unix system - setup MATLAB (return)

MATLAB
Command
Window

On both system leave a MATLAB session by typing :

>> quit
or by typing
>> exit

History

at the MATLAB prompt.

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Getting started with MATLAB

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Algebraic operations in MATLAB:

Scalar Calculations:
+
addition
subtraction
*
multiplication
/
right division (a/b means a b)
\
left division (a\b means b a)
^
exponentiation
For example

>>
>>
>>
>>

3*4
executed in 'MATLAB' gives ans=12
4/5
gives ans=.8
4\5
ans=1.25
x = pi/2; y = sin(x)
y=1

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Matrix, vector and scalar:

MATLAB

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Syntax in MATLAB:
Colon operator: The colon operator ' : ' is understood by Matlab to perform special
and useful operations.

uses variables that are defined to be matrices.

For example, if two integer numbers are separated by a colon, Matlab will generate
all of the integers between these two integers.

A matrix is a collection of numerical values that are organized into a specific

configuration of rows and columns. The number of rows and columns can be any
number.

a = 1:8

A=[ 1 2 3 4
5 6 7 8];

generates the row vector, a = [ 1 2 3 4 5 6 7 8 ].

If three numbers, integer or non-integer, are separated by two colons, the middle
number is interpreted to be a step" and the first and third are interpreted to be "limits:

A is for example, 2 rows and 4 columns define a 2 x 4 matrix which has 8 elements
in total.
A scalar is represented by a 1 x 1 matrix in MATLAB:

b = 0.0 : .2 : 1.0

a=1;

generates the row vector b = [ 0.0 .2 .4 .6 .8 1.0 ]

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Matrix, vector and scalar:

A vector of n elements can be represented by a n x 1 matrix, in which case it is
called a column vector, or a vector can be represented by a 1 x n matrix, in which
case it is called a row vector of n elements.
x = [ 3.5, 33.22, 24.5 ] ;

x is a row vector or 1 x 3 matrix

x1 = [ 2
5
3
-1];

x1 is column vector or 4 x 1 matrix

The matrix name can be any group of letters and numbers up to 19, but always
beginning with a letter.
MATLAB is "case sensitive", that is, it treats the name 'C' and 'c' as two different
variables.
Similarly, 'MID' and 'Mid' are treated as two different variables.

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Syntax in MATLAB:
The colon operator can be used to create a vector from a matrix.
Thus if
x=[2 6 8
0 1 7
-2 5 -6 ]
The command

y = x(:,1) creates the column vector

y=[ 2
0
-2 ]

The command z = x(1,:) creates the row vector

z=[2 6 8]

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Syntax in MATLAB:

Some basic commands you may need:

The colon operator is useful in extracting smaller matrices from larger matrices.
If the 4 x 3 matrix c is defined by
c = [ -1 0
1 1
1 -1
0 0
Then

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0
0
0
2]

figure

creates an empty figure window

close

by itself, closes the current figure window

hold on holds the current plot and all axis properties so that subsequent graphing
commands add to the existing graph

d1 = c(:,2:3)

>> figure; x=0:.01:2*pi; Y=sin(x); plot(x,Y);hold on; Y=sin(2*x);plot(x,Y);

creates a matrix for which all elements of the rows from the 2nd and third columns
are used. The result is a 4 x 2 matrix
hold off sets the next plot property of the current axes to "replace
d1 = [ 0
1
-1
0

0
0
0
2]

hold off is the default.

>> figure; x=0:.01:2*pi; Y=sin(x); plot(x,Y);hold off; Y=sin(2*x);plot(x,Y);

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Some basic commands you may need:

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Some basic commands you may need:

find

pwd

find indices of nonzero elements e.g.:

d = find(x>100) returns the indices of the vector x that are greater than 100

prints working directory

>> pwd

>> x = [120, 90, 100, 30, 220, 98, 12, 78, 900]; d = find(x>100)
d=

ans =

C:\INSE6220
>> load parts
whos: lists all of the variables in your MATLAB workspace
>> whos
Name
runout

Size
36x4

Bytes Class
1152 double array

Grand total is 144 elements using 1152 bytes

break terminate execution of m-file or WHILE or FOR loop

for repeat statements a specific number of times, the general form of a FOR
statement is:
FOR variable = expr, statement, ..., statement END
a = zeros(k,k) % Preallocate matrix
for m = 1:k
for n = 1:k
a(m,n) = 1/(m+n -1);
end
end

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Descriptive Statistics

Statistics with MATLAB

Online help for Statistics Toolbox is available from the Matlab prompt (>> a
double arrow), both generally (listing of all available commands):
>> help stats
[a long list of help topics follows]
and for specific commands:

corrcoef - Linear correlation coefficient with confidence intervals.

cov
- Covariance.
mean
- Sample average (in MATLAB toolbox).
median - 50th percentile of a sample.
range
- Range.
std
- Standard deviation (in MATLAB toolbox).
var
- Variance (in MATLAB toolbox).

>> help distool

Example:
>> X = [ 1 2 3 5 6 7 23 45 33 46 22]
X=
1 2 3 5 6 7 23 45 33 46 22
>> mean(X)

[a help message on the disttool function follows].

>> help disttool
DISTTOOL Demonstration of many probability distributions.
DISTTOOL creates interactive plots of probability distributions.
This is a demo that displays a plot of the cumulative distribution
function (cdf) or probability distribution function (pdf) of the distributions
in the Statistics Toolbox.

ans =
17.5455
>> std(X)
ans =
17.2648

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Plotting Probability Distributions

>> disttool

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Statistical Plotting

andrewsplot - Andrews plot for multivariate data.

biplot - Biplot of variable/factor coefficients and scores.
boxplot - Boxplots of a data matrix (one per column).
cdfplot - Plot of empirical cumulative distribution function (cdf).
fsurfht - Interactive contour plot of a function.
glyphplot - Plot stars or Chernoff faces for multivariate data.
gplotmatrix - Matrix of scatter plots grouped by a common variable.
gscatter - Scatter plot of two variables grouped by a third.
hist
- Histogram (in MATLAB toolbox).
hist3
- Three-dimensional histogram of bivariate data.
normplot - Normal probability plot.
parallelcoords - Parallel coordinates plot for multivariate data.
probplot - Probability plot.
surfht - Interactive contour plot of a data grid.
wblplot - Weibull probability plot.

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Statistical Plotting using MATLAB

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Control chart using MATLAB

Create a Pareto chart from data measuring the

number of manufactured parts rejected for
various types of defects.

Syntax: controlchart(data,chart,charttype)
>> load parts
>> st = controlchart(runout,'chart',{'xbar' 'r'})

>> defects = {'pits';'cracks';'holes';'dents'};

>> quantity = [5 3 19 25];
>> pareto(quantity,defects);

Boxplot(X) produces a box and whisker plot for

each column of the matrix X. The box has lines
at the lower quartile, median, and upper quartile
values. The whiskers are lines extending from
each end of the box to show the extent of the
rest of the data. Outliers are data with values
beyond the ends of the whiskers
>> load parts
>> boxplot(runout);

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Statistical Process Control (SPC)

capable - Capability indices.

capaplot - Capability plot.
capability - Capability indices.
ewmaplot - Exponentially weighted moving average plot.
histfit - Histogram with superimposed normal density.
normspec - Plot normal density between specification limits.
controlchart - Shewhart control chart.
controlrules - Control rules (Western Electric or Nelson) for SPC.

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Tips for success

Expect to spend enough time studying the material of the course

Start every assignment early
Dont fall behind
Ask if you dont know
Do your own work

Reading: course notes

Assignment #1
To be posted soon on the course webpage