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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 To apply control charts to monitor the quality characteristics of a product or
process
Introduction to Statistical Quality Control Learn techniques for multivariate process monitoring and diagnosis
Design and analyze experiments for improving a manufacturing process
Learn how to use acceptance sampling

You do not need prior knowledge of MATLAB programming.

Previous experience with programming is desirable but not essential.

Dr. A. Ben Hamza Concordia University

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Roadmap of the Course?

Instructor: Dr. A. Ben Hamza
INSE 6220

Office: EV 7.631

Lectures: Monday 5:45 - 8:15

Statistical Engineering
Process Quality
Process Control Process Control

Office Hours: Monday 3:00 - 4:00

Experimental
E-Mail: hamza@ciise.concordia.ca
Modeling Inferences Statistical
Methods
Control Charts Multivariate
Design

Capability Acceptance
Analysis Sampling

Midterm Exam Final Exam

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Administration What this course is about?

Course web page:
MyConcordia Portal (Moodle) This course is about Advanced Statistical Techniques for Quality
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
Preliminary exam dates and project due date: To learn how to apply control charts to monitor the quality
characteristics of a product or process
Midterm Exam
February 27, 2017 (in class) To learn techniques for multivariate monitoring and diagnosis
Project due To design and analyze experiments for improving a manufacturing
April 16, 2017 (Sunday by midnight) process
Final Exam To learn how to use acceptance sampling
April ??, 2017 (TBA)

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Grading Policy What is statistics?

Important Dates: The science of collecting, organizing, analyzing, and interpreting data in
Feb 13, 2017: Assignment #1 due
order to make decisions.
Two Assignments 10%
Midterm Exam 35%
Feb 27, 2017: Midterm Exam Methods for processing and analyzing numbers
Project 10%
Apr 3, 2017: Assignment #2 due
Apr 16, 2017: Project Report due
Methods for helping reduce the uncertainty inherent in decision making
Final Exam 45% Apr ??, 2017: Final Exam
Why Learn Statistics?
So you are able to make better sense of the ubiquitous use of numbers:
Final Project Business memos
Software defect data
Final reports due on April 16, 2017 before midnight. Quality control
A final project report, completed individually is required. Data mining
The term project will have only one component: written report. Machine learning
More details will be posted on: MyConcordia Portal (Moodle) Artificial intelligence
Quality assurance
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What is Statistics? What is Quality?

Fitness for Use

1. Collecting Data Data Why?
Conformance to Specifications
e.g., Survey Analysis Producing the Very Best Products
2. Presenting Data Excellence in Products and Services
e.g., Charts, Graphs & Tables
Total Customer Satisfaction
Decision- Exceeding Customer Expectations
3. Characterizing Data Making
e.g., Average Quality improvement starts with reducing Product VARIABILITY.

1984-1994 T/Maker Co.

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What is Quality? Quality - Whats the Big Deal?

What makes a good quality Direct Costs of Poor Quality:
car Lost Revenue: scrap, rework, repair
computer
Lost Productivity: materials, machines, and personnel
knife
childrens toy
Inspection Costs: inspectors, testing machines
pizza delivery External Costs: warranty claims, price adjustments, late charges

Describe a recent time when you Indirect Costs of Poor Quality - Upset Customers:
have experienced bad quality?
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.
So what are the common aspects of
quality? Satisfied customers only tell 3-5 people.
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Expressing Dissatisfaction Quality Improvement

Improve quality
Quality is better if variability in the important quality characteristics of a product
Public action decreases.
can be
Quality improvement is the reduction of variability in processes and products.
Seeking redress directly from
Takes
action
the firm Quality characteristics
Taking legal action
A dissatisfied
A complaint to business, private,
Types
customer or governmental agencies Physical: Length, weight, volume, viscosity,
Sensory: taste, appearance, color,
Private action
Time orientation: reliability, durability, serviceability,
Stop buying the product or
boycott the seller Data are needed to characterize quality characteristics
Takes
no action
Warn friends about the product
and/or seller
Data can be classified
Attributes discrete
Variables continuous

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Eight Dimensions of Quality Quality Engineering

The operational, managerial, and engineering activities that a company uses to ensure
1. Performance: Will the product do the intended job? that the quality characteristics of a product are at the nominal or required levels.

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
product?
8. Conformance to Standards: Is the product made exactly as the
designer intended?
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.
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Key Definitions in Statistics Why a Manager Needs to

Know about Statistics
A population (universe) is the collection of things under
consideration
To know how to properly present information -
KNOWLEDGE
A sample is a portion of the population selected for To know how to draw conclusions about populations
analysis based on sample information
A parameter is a summary measure computed to To know how to improve processes- IF YOU DONT
describe a characteristic of the population KNOW WHATS GOING ON, YOU CAN NEVER
IMPROVE A PROCESS
A statistic is a summary measure computed to describe a
characteristic of the sample

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Statistical Process Control

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

Inference on the population from the sample

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SPC/Control Chart Six Sigma

Control charts Use of statistics & other analytical tools has grown steadily for over 93 years
Useful in monitoring processes, Statistical quality control (origins in 1920, explosive growth during WW II,
On-line technique 1950s)
Walter A. Shewart (1891-1967) Operations research (1940s)
TQM (Total Quality Management) movement in the 1980s
Bell Labs, developed the first control chart about 1924
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.

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Design of Experiments Six Sigma

The fundamental objective of the Six Sigma methodology is the implementation
Discovering the key factors that influence process performance of a measurement based strategy that focuses on process improvement and
Process optimization variation reduction. This is accomplished through the use of DMAIC
(Define, D
Measure,
efine Analyze, Improve, Control)
Off-line technique
Define Define the problem and customer
Measure 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
A factorial experiment with three factors
ensure that defects do not recur.

Improve Analyze
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Companies implementing Six Sigma

How to start and quit MATLAB?
Motorola DuPont
Texas Instruments American Express
ABB BBA PC - a double click on the MATLAB icon on
AlliedSignal
Ford your desktop
Dow Chemical
GE Johnson Controls unix system - setup MATLAB (return)
Bombardier Noranda MATLAB
Nokia Toshiba
On both system leave a MATLAB session by typing :
>> quit
or by typing
>> exit

at the MATLAB prompt.

3.4 defects per million opportunities (DPMO)

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Six Sigma TrainingBlack Belt Program Getting started with MATLAB

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 Matrix, vector and scalar:

MATLAB uses variables that are defined to be matrices.

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

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

A=[ 1 2 3 4
Command 5 6 7 8];
Window
A is for example, 2 rows and 4 columns define a 2 x 4 matrix which has 8 elements
in total.
History
A scalar is represented by a 1 x 1 matrix in MATLAB: a=1;

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Algebraic operations in MATLAB: Matrix, vector and scalar:

Scalar Calculations: A vector of n elements can be represented by a n x 1 matrix, in which case it is
+ addition called a column vector, or a vector can be represented by a 1 x n matrix, in which
- subtraction case it is called a row vector of n elements.
* multiplication
/ right division (a/b means a b) x = [ 3.5, 33.22, 24.5 ] ; x is a row vector or 1 x 3 matrix
\ left division (a\b means b a)
x1 = [ 2 x1 is column vector or 4 x 1 matrix
^ exponentiation 5
3
For example >> 3*4 executed in 'MATLAB' gives ans=12 -1];
>> 4/5 gives ans=.8
>> 4\5 ans=1.25 The matrix name can be any group of letters and numbers up to 19, but always
beginning with a letter.
>> x = pi/2; y = sin(x) y=1
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: Syntax in MATLAB:

Colon operator: The colon operator ' : ' is understood by Matlab to perform special The colon operator is useful in extracting smaller matrices from larger matrices.
and useful operations. If the 4 x 3 matrix c is defined by

For example, if two integer numbers are separated by a colon, Matlab will generate c = [ -1 0 0
all of the integers between these two integers. 1 1 0
1 -1 0
a = 1:8 0 0 2]
Then
generates the row vector, a = [ 1 2 3 4 5 6 7 8 ].
d1 = c(:,2:3)
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: 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
b = 0.0 : .2 : 1.0
d1 = [ 0 0
generates the row vector b = [ 0.0 .2 .4 .6 .8 1.0 ] 1 0
-1 0
0 2]

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Syntax in MATLAB: Some basic commands you may need:

The colon operator can be used to create a vector from a matrix.
Thus if pwd prints working directory
x=[2 6 8
>> pwd
0 1 7
-2 5 -6 ] ans =

The command y = x(:,1) creates the column vector C:\INSE6220

y=[ 2
>> load parts
0 whos: lists all of the variables in your MATLAB workspace
-2 ]
>> whos
Name Size Bytes Class
The command z = x(1,:) creates the row vector
runout 36x4 1152 double array
z=[2 6 8]
Grand total is 144 elements using 1152 bytes
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Some basic commands you may need: Plotting Probability Distributions

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

hold off sets the next plot property of the current axes to "replace
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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Statistics with MATLAB Descriptive Statistics

corrcoef - Linear correlation coefficient with confidence intervals.
Online help for Statistics Toolbox is available from the Matlab prompt (>> a
cov - Covariance.
double arrow), both generally (listing of all available commands):
mean - Sample average (in MATLAB toolbox).
>> help stats median - 50th percentile of a sample.
[a long list of help topics follows] range - Range.
std - Standard deviation (in MATLAB toolbox).
and for specific commands:
var - Variance (in MATLAB toolbox).
>> help distool Example:
>> X = [ 1 2 3 5 6 7 23 45 33 46 22]
[a help message on the disttool function follows]. X=
1 2 3 5 6 7 23 45 33 46 22
>> help disttool >> mean(X)
DISTTOOL Demonstration of many probability distributions. ans =
DISTTOOL creates interactive plots of probability distributions. 17.5455
This is a demo that displays a plot of the cumulative distribution >> std(X)
function (cdf) or probability distribution function (pdf) of the distributions ans =
in the Statistics Toolbox. 17.2648
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Statistical Plotting using MATLAB Control chart using MATLAB

Create a Pareto chart from data measuring the
number of manufactured parts rejected for Syntax: controlchart(data,chart,charttype)
various types of defects. >> load parts
>> defects = {'pits';'cracks';'holes';'dents'}; >> st = controlchart(runout,'chart',{'xbar' 'r'})
>> 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) Tips for success

capable - Capability indices.
capaplot - Capability plot.
Expect to spend enough time studying the material of the course
capability - Capability indices. Start every assignment early
ewmaplot - Exponentially weighted moving average plot. Dont fall behind
histfit - Histogram with superimposed normal density. Ask if you dont know
normspec - Plot normal density between specification limits. Do your own work
controlchart - Shewhart control chart.
controlrules - Control rules (Western Electric or Nelson) for SPC.

Reading: course notes

Assignment #1
To be posted soon on the course webpage