Handbook for Quality Technicians & Mechanical Inspectors

by Thomas Pyzdek

I Quality control concepts and techniques 1

A Total quality control concepts 1

1 New design control 1

2 Purchased material control 5

3 Product and process control 12

4 Special processes control 18

5 Work elements of quality systems 19

B Classification of characteristics and nonconformances 26

C Determination of inspection points and methods 28

1 Purchased material 33

2 Work in process 33

3 Final inspection and test 39

4 Shipping inspection 41

5 Documentation methods 42

D Inspection methods 43

1 100% inspection 43

2 Different types and methods of sampling 48

3 Nondestructive testing and examination 49

4 Destructive testing 51

E Nonconforming material control 51

1 Identification and segregation 51

2 Materials review principles 62

3 Dispositions 63

4 Corrective action and recurrence control 63

F Quality data 64

1 Purposes 66

2 Uses 66

3 Analysis 68

4 Application to problem solving 69

G Quality Tools 70

1 PDCA (Plan-Do-Check-Act) 70

2 Principles of team leadership and facilitation 75

3 Team dynamics management, including conflict resolution 77

H Basic probability concepts 84

II Fundamentals of practical statistical methods 91

A Presentation, description, and analysis of data 91

1 Frequency distribution of data: normal, bimodal, skewed 91

2 Measurement of central tendency 103

3 Measurement of variation 104

4 Measurement of correlation 105

B Sampling distributions 114

1 Mean 114

2 Variance 114

3 Proportion 115

4 Range 115

5 Normal 116

6 Poisson 120

7 Binomial 121

8 Pareto 122

C Statistical inference 125

D Control charts 139

1 General concepts 139

2 State of statistical control 144

3 Control limits 146

4 Pre-control 149

5 Process capability 153

6 Rational subgroupings 165

7 Variables charting 166

8 Attribute charting 181

9 Machine capability 197

10 Analysis of charts 200

III Application of sampling principles 217

IV Reliability principles, applications, and simple calculations 237

V Metrology and calibration fundamentals 257

A Common international standards of measurement 263

B Measurement standards and traceability 265

VI Quality data, analysis, problem solving, and cost methodology 325

VII Quality audit concepts and principles 349

VIII Technical Mathematics 369

A Shop math 369

1 Fractions 369

2 Decimals 373

3 Squares 378

4 Square roots 378

B Algebra 379

1 Use of letters and signed numbers 379

2 Fundamental operations in algebra 386

C Plane geometry 396

1 Parallel lines 402

2 Congruence 406

3 Similar triangles 411

4 Circles 415

5 Equivalent areas 423

6 Special points of a triangle 425

D Trigonometry 429

1 Angles and measurements 430

2 The trigonometric functions 443

3 Problems involving right triangles 460

4 Problems involving oblique triangles 468

Appendix 499

Table 1 Quality Auditing terminology 501

Table 2 Audit standards and standards organizations 514

Table 3 Glossary of basic statistical terms 516

Table 4 Area under the standard normal curve 524

Table 5 Critical values of the t-distribution 527

Table 6 Chi-square distribution 529

Table 7 F distribution (a=1%) 532

Table 8 F distribution (a=5%) 534

Table 9 Poisson probability sums 536

Table 10 y factors for computing AOQL 540

Table 11 Control chart constants 541

Table 12 Control chart equations 543

Table 13 Mil-Std-45662 Military standard: calibration system requirements 545

Table 14 Table of d2* values 555

Table 15 Equivalent measurements of angles 557

Table 16 Right angles expressed in degrees and radians 558

Table 17 Degrees and minutes expressed in radians 559

Table 18 Signs of the trigonometric functions 560

Table 19 Values of the trigonometric functions, q as multiple of 90° 561

Table 20 Values of the trigonometric functions, q ± multiples of 90° in terms of q 562

Table 21 Values of the trigonometric functions, q at selected intervals 563

Table 22 Greek alphabet 564

Table 23 Values of the trigonometric functions, sin, cos, tan, cot 565

Table 24 Logarithms of trigonometric functions 572

Table 25 Mathematical notation 579

Table 26 Metric interrelationships 580

Table 27 Conversions, weights, and measures: equivalents 582

References 587

Index 593

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