ime415s09

California State Polytechnic University, Pomona
IME 415 Quality Control by Statistical Methods
Spring 2009
Revised 5/21/09

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Dr. Phillip R. Rosenkrantz, P.E.
Office Phone: 909-869-2553, Office FAX: 909-869-2564 Office: 17-2690
email: rosenkrantz@csupomona.edu URL: http://www.csupomona.edu/~rosenkrantz
Office Hours: M 10:00-11:00 a.m, 1:30-2:30 p.m., Tu 2:30-3:30 p.m.. W 11:00-12:00 a.m, 1:30-2:30 p.m. , Posted by office (call first if convenient--see Policies and Procedures). ( Click here to see Dr. Rosenkrantz' full schedule)

Texts: (1) Montgomery, Introduction to Statistical Quality Control, Wiley & Sons, Sixth Edition, 2008,
(2) Six Sigma Memory Jogger, Goal/QPC (download sample) (3) Your team book as assigned
Software: Minitab Release 15 (Student prices available for download: 30 day free trial, 6 month rental ($29.99), 1 year rental (($49.99), perpetual version, ($99.99)), Microsoft EXCEL (v4.0 or later) and PowerPoint
Note: Students are responsible for dates below even if reminders are not given in class.
Class Day Date Read Prior to Class Description Assignments (see Bb for detail)/Quizzes

- T 3/31 -
Cesar Chavez Holiday

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1 TH 4/2 Ch. 1, 2, 3
Introduction, History, Statistical Background, Definitions. Tools Methods and Philosophy of SPC: Introduction to Process Capability

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2 T 4/7 Ch. 4, 7, 5 Introduction to Process Capability, Methods and Philosophy of SPC,

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Lab 1 TH 4/9 - SPC Simulation (Part 1)
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3 T 4/14 Ch. 6 Charts for Variables Ch 1 & 2 Hmwk due

Lab 2 TH 4/16 - SPC Simulation (Part 2)
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4 T 4/21 Ch. 6 Charts for Variables Ch 3 & 4 Hmwk due

Lab 3 TH 4/23 -
SPC Simulation (cont'd)

Quiz #1 - Ch.1, 2, & notes

5 T 4/28 Ch. 7 Charts for Attributes
Ch 5 Hmwk Due

Lab 4 TH 4/30 - DOE
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6 T 5/5 Ch. 8 Process Capability Ch 6, 7 Hmwk due

Lab 5 TH 5/7 - , Book Report Meeting
Quiz #2 - Ch. 3, 4 & 5

7 T 5/12 Ch. 9 CUSUM and EWMA Charts, Other Techniques Ch 8 Hmwk due

Lab 6 TH 5/14 - Root Cause Analysis, (Part 2) Professor for a Day
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8 T 5/19 Ch. 10.1-10.3 Process Control Plans
Quiz #3 - Ch. 6, 7 (practice .doc .rtf)-

Lab 7 TH 5/21 -
Root Cause Analysis (Part 1)

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9 T 5/26 - Quiz #2 Retake, Six Sigma, Process Control Plans

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Lab 8 TH 5/28 - Quality Management (Special Presentation) Ch, 9, 10 Hmwk due

- T 6/2 -

Root Cause Analysis (Part 2)

Quiz #4 - Ch. 8 (practice .rtf)

Lab 9 TH 6/4 -
Topic Presentations & Discussion
(Pres. ppt files due 6/2 by email 12 midnight)

Sample Quiz #5
Sample Quiz #6

FINAL EXAM: Tuesday, June 9, 2009, 7:00 a.m.- 9:00 a.m.
Quiz #5 - Ch. 9, 10 & Quiz #6 (Covers Ch. 1-10 + Presentations. Bring Scantron 882) Spring Finals Schedule

Grading will be based on the following:

Quizzes - Best 5 out of 6 quizzes. Must have passing average (60% or more) to pass the course. Retake Quiz #2 until grade of 80% or more is achieved.	50%
Homework - Includes any threaded discussions	10%
Class participation - Mostly attendance and punctuality in lecture classes	5%
Lab Projects and Assignments (15% team lab assignments, attendance, and participation, 10% individual assignments)	25%
Topic or Book Report Presentations (part team and part indiv)	10%

Supplemental Policies and Procedures


INTRODUCTION - IME 415 is an upper division, major course that is a crucial part of the body of knowledge for your degree. It is expected that you have planned for an adequate amount of energy and time to complete the course assignments and study appropriately. If you do not expect to have time to give this course the attention it deserves, it is suggested that you take it later.

QUIZZES - Quizzes will be given at the end of class and last approximately 20-30 minutes. Quizzes will cover computational/problem solving ability, concepts, terminology, and depth of understanding. See the section below that describes the Minimum Knowledge Requirements. The final two quizzes will be given during final exam week. Quiz #6 will cover material from the entire course and gives the student an opportunity to display mastery of the subject.

Grade
Definition per University Catalog
Interpretation for IME 415. Specific knowledge and skills that reflect mastery levels.

A Superior Work - Reflects originality and independent work and a thorough mastery of the subject matter/skill: achievement so outstanding that it is normally attained by students doing truly exemplary work. Meets the Minimum Knowledge Requirement (see below) and achieves a 90% or better average on all combined work. Understands SPC well enough to apply it to a real situation and set up a process control plan. Understands how to calculate Type 1 & Type II error proficiently and can design a control chart to guard against specific Type I and Type II errors. Proficient in the use of terminology related to quality.

B Very Good Work - Indicates clearly better than adequate competence in the subject matter/skill; achievement of quality higher than adequate, but not of exemplary quality. Meets the Minimum Knowledge Requirement and achieves a 80% or better average on all combined work. Understands SPC well enough to apply it to a real situation and set up a process control plan. Can quickly recommend which type of control chart to use in a given situation.

C Adequate Work - Indicates that classroom work, outside assignments, and examinations have been completed at a level indicating adequate competence in the subject matter/skill. Meets the Minimum Knowledge Requirement and demonstrates working knowledge of SPC. Can set up control charts and generally choose the proper chart for a given situation. Achieves a 70% or better average on all combined work.

D Minimally Acceptable Work - Indicates achievement which meets the minimum requirements of the course, but at a level indicating less than adequate competence in the subject matter/skill. Meets the Minimum Knowledge Requirment and achieves a passing average on all other work.

F Unacceptable Work - Indicates achievement that fails to meet the minimum requirements of the course and is clearly below university quality; not a passing grade. Does not meet the Minimum Knowledge Requirement and/or does not achieve a passing average on all combined work.
IME 415 Minimum Knowledge Requirements (largely covered in Chapters 3 & 5, 6, 7) - Regardless of anything else, students will not get a passing grade in IME 415 if they cannot demonstrate the following:

Basic Statistics - Understand and know how to use the formulas and tables for the hypergeometric, binomial, Poisson, and normal distributions. This includes knowing how to use the cumulative forms of each distribution. Must be able to quickly use the z-transformation and tables for finding normal probabilities. Know the difference between population distributions and sampling distributions.

Process Control/Philosophy - Understand and be able to explain and apply Shewhart's concept of process control. Be able to discern whether or not a process is in a state of "statistical control". This is not just the ability to find the definition in Chapter 5 and regurgitate it on a quiz. The idea of "statistical control" is central to the entire course. No student deserves to pass the course who does not understand this concept. Understand and be able to articulate the Shewhart/Deming's philosophy of "assignable cause" vs. "common cause" variation. Understand the basic management issues that seem to make implementation of SPC difficult in some organizations. Be familiar with Demings 14 points and Theory of Profound Knowledge.

Process Capability - Understand and be able to explain the concept of process capability. Clearly understand the difference between "process capability" and "process control". Be able to calculate the estimates for process capability indices Cp, Cpk, Cpm given the raw data and process specifications. Be able to explain the "Six-Sigma" quality concept.

Control Charts - Given data, be able to construct common variable (x-bar, R, & S-charts, I & MR) and attribute (p, np, c, u) control charts, plot and interpret the data, make revisions as necessary.

NOTE: IT IS THE STUDENT'S INDIVIDUAL RESPONSIBILITY TO LEARN THE MATERIAL AND MEET THE MINIMUM KNOWLEDGE REQUIREMENT. IF THE INFORMATION PRESENTED IN CLASS, THE TEXT, OR THROUGH ASSIGNMENTS IS NOT SUFFICIENT FOR YOU TO MEET THE REQUIREMENT, THEN YOU ARE RESPONSIBLE FOR RESEARCHING THE LIBRARY, INTERNET, PROFESSIONAL RESOURCES, OR WHATEVER IT TAKES TO GET THE INFORMATION YOU NEED.

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