Project file

Inspection and quality control

Submitted to Submitted
by
Shri. Bharat Singh Yadav
MOHAN
PAL Lecturer (IQC)

1508131228

Mechanical [E] MR. ABHIJEET CHATTERJEE

( Lect. Mechanical engg. Dept.)

TH
5 Semester

AT

PUSA INSTITUTE OF TECHNOLOGY

NEW DELHI-110012
 3

Contents 4
7
CHAPTER – 1 INTRODUCTION
11
CHAPTER=2, PERFORMANCE OF EXPERIMENTS 13
EXPERIMENT :- 1 15
EXPERIMENT 2 18
EXPERIMENT :-3
21
EXPERIMENT :-4
26
EXPERIMENT :- 5
EXPERIMENT:-6

CHAPTER-3 Conclusion Of Project

CHAPTER – 4 REFRENCES

3
CHAPTER – 1 INTRODUCTION

I n order to know about the importance of quality control and quality control charts and to complete my project

on various quality charts and all the data or observations in the project are done by me.

We have studied a no. of practical in IQC like X Bar and R chart, p chart, nP chart, C chart, and OC chart on minor
level. Now we are going to study these charts more accurately by applying them on actual large no. of components
practically say about hundreds. This can allow us to understand these charts more by difference in them with actual
condition. My components are buttons which is daily used items like in clothes (shirts, pant etc.), which are of
different in colors and at least of same dimension of diameters and thickness.

Now I am going to perform these practical on my component (buttons) to get different result,
conclusion and overall conclusion by which we can learn these charts or practical more precisely. The quality charts
are as follows :-

• X bar and r chats .

• P and NP charts .
• C charts.
5
• OC curves etc.
CHAPTER=2, PERFORMANCE OF EXPERIMENTS

EXPERIMENT :- 1

AIM :- To calculate mean , mode, median, standard deviation and variance for a specimen.
MEAN IS THE AVERAGE
Mean is a measure of central tendency. It measures what the majority of the data are doing toward the middle of a
set. The mean is often referred to as the average of a data set

MODE OCCURS MOST

Mode is another measure of central tendency. The mode is just the number that occurs most frequently. It's easy to
remember because mode and most sound alike. Using the algebra class example, what grade occurred most
frequently among the students? To answer, put the values in order:
MEDIAN IS THE MIDDLE, RANGE IS THE SPREAD
Median is another measure of central tendency. The median is simply the middle number of a set. Put the numbers
in order and look for one in the middle. If there is no middle number, add the two in the center and divide by 2. In
the algebra class example, what is the median grade? To answer, put the values in order:
STANDARD DEVIATION
Standard deviation is the measure of how spread out the numbers are from the center of a data set. A small
standard deviation means a lot of the numbers are grouped around the middle of the set. A large standard
deviation means that the number are spread out with some very high and low numbers. With the algebra grades,
use this equation:

Variance
Variance is the average of the squared difference of each number from the mean. That may sound confusing, but
it's pretty simple to do. Take each number in the set and subtract if from the mean. Then square it. Add those
values together, and divide by the number of items in your set. Working with the algebra class grades again,
subtract each one from the mean:

(NOTE:- ALL DIEMENSIONS ARE IN MM)

7
Observation Table

S. no. Diameter (d) Thickness (t) 34 11 1

1 11 1 35 11 1
2 11 1 36 11 1
3 11 1 37 11 1
4 11 1 38 11 1
5 11 1 39 11 1
6 11 1 40 11 1
7 11 1 41 11 1
8 11 1 42 11.5 1.5
9 11 1 43 11.5 2
10 11 1 44 11.5 2
11 11 1 45 11.5 2
12 11 1 46 11.5 2
13 11 1 47 11.5 2
14 11 1 48 11.5 2
15 11 1 49 11.5 2
16 11 1 50 11.5 2
17 11 1 51 11.5 2
18 11 1 52 11.5 2
19 11 1 53 11.5 2
20 11 1 54 11.5 2
21 11 1 55 11.5 2
22 11 1 56 11.5 1.5
23 11 1 57 11.5 1.5
24 11 1 58 11.5 1.5
25 11 1 59 11.5 1.5
26 11 1 60 11.5 1
27 11 1 61 11.5 1
28 11 1 62 11.5 2
29 11 1 63 11.5 2
30 11 1 64 11.5 2

8
31 11 1 65 11.5 2
32 11 1 66 11.5 4
33 11 1 67 11.5 2.5
68 11.5 2.5
69 11.5 2.5
70 11.5 1.5
71 11.5 1.5
72 11.5 1.5
73 11.5 1.5
74 11.5 3
75 11.5 3
76 13 3
77 13 2
78 13 2.5
79 13 2.5
80 13 2
81 13 2
82 13 3
83 13 3
84 13 3
85 13 1.5
86 13 1.5
87 10 1.5
88 10 1.5
89 13 2.5
90 12 1.5
91 12 1.5
92 9 2.5
93 9 2.5
94 10 3
95 10 3
96 9 3
97 13 3.5
98 14 2

9
 99 14 2 RESUL/CONCLUSION:-
100 12 2.5
Total 1142 166.5
For Diameter :-
Mean for diameter = 11.42 mm Mode for diameter = 11 mm Median for diameter = 11.5 mm Standard
Deviation =0.8981462390205 mm
Variance =0.8067 mm

For Thickness :-
Mean for thickness = 1.665 mm Mode for thickness = 1 mm Median for thickness = 2mm Standard
Deviation =0.73186837145167 mm Variance = 0.53563131313131 mm

EXPERIMENT 2

Aim :-To construct X-bar and R chart of the quality characteristics for given production process.

10
Theory
A control chart is a graphical display of quality characteristics that has been measured or computed from a
sample versus the sample number or time. The chart contains a centre line which represents the average
value of the quality characteristic corresponding to the in-control state. Two control limits (UCL, LCL) are
chosen so that if the process is in control, nearly all of the sample points will fall between them. It is also
an estimating device which exhibits statistical control of such process parameters like the mean, standard
deviation, fraction, non- conforming or fall- out and so forth. These estimates may then be used to determine
the capability of the process to produce acceptable products.

UCL = Upper control limit

CL = Central Line

LCL = Lower control limit

Where,

• 𝐴2 = 0.73 𝐷4 = 2.28
• 𝐷3 = 0
• X-bar = Mean of Subgroups
• X-double bar = Mean of X-bar
• R = Range of Subgroups
• R-bar = Mean of Subgroups Range

(NOTE:- ALL DIEMENSIONS ARE IN MM)

Observation Table

sample 1 2 3 4 5 X bar R

11
1 11 11 13 11 11 11.4 2

2 11 11 9 12 11.5 10.9 3

3 11 11 11.5 11.5 9 10.8 2.5

4 11 11 11.5 11.5 11.5 11.3 0.5

5 11 11.5 10 12 13 11.5 3

6 11 11.5 11.5 11 11 11.2 0.5

7 11 11.5 13 14 11 12.1 3

8 11 11.5 11 10 10 10.7 1.5

9 11 11.5 11.5 11.5 11.5 11.4 0.5

10 11 11 11 11 14 11.6 3

11 11 11 11 11 13 11.4 2

12 11.5 11.5 11.5 11.5 9 11 2.5

13 11.5 11.5 11.5 11.5 11 11.4 0.5

14 11.5 11.5 11.5 11.5 11 11.4 0.5

15 13 13 13 11 11 12.2 2

16 13 13 13 11 11 12.2 2

17 13 13 13 11 11 12.2 2

18 10 11.5 11.5 11.5 11 11.1 1.5

19 11.5 11.5 11.5 11.5 11 11.4 0.5

20 11 11 11 12 11 11.2 1

11.42 1.7

12
 X Bar Chart
13
12.5
12
11.5 Series1

11 Series2

10.5 Series3

10 Series4

9.5
9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Series 1 = X-Bar Value Series 2 = LCL

Series 3 = CL (Mean Value) Series 4 = UCL

X̅ Chart
̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅X̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 11.42 mm CL = 11.42 mm

LCL = 10.44 mm UCL = 12.40mm

R Chart
4
3.5
3
2.5 Series1

2 Series2

1.5 Series3

1 Series4

0.5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Series 1 = Range Value Series 2 = LCL
Series 3 = CL (Mean Value) Series 4 = UCL

13
R Chart
̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
R̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 1.7 mm CL = 1.7 mm UCL = 3.59 mm
LCL = 0.000 mm

Conclusion

• Any point falling outside the control limits indicates that assignable causes had affected the process
and the process is out of control. Looking into the X bar chart it is observed that all the points are
falling within the control limits. It means that the assignable cause does not affect the process.
• Looking into the R chart it is observed that all the points are falling within the control limits. It
means that the assignable cause does not affect the process.

14
 EXPERIMENT :-3

Aim – To construct p chart (fraction effective chart).

Theory:- This procedure generates the P control chart for the fraction of a sample that is nonconforming. The
format of the control charts is fully customizable. This procedure permits the defining of stages. For the P
chart, the value for P can be entered directly or estimated from the data, or a sub-set of the data. A list of out-
ofcontrol points can be produced in the output, if desired, and proportion nonconforming values may be stored
to the spreadsheet. P Control Charts P charts are used to monitor the proportion of nonconforming units of a
process based on samples taken from the process at given times (hours, shifts, days, weeks, months, etc.).
Typically, an initial series of samples is used to estimate proportion nonconforming of a process. The estimated
proportion is then used to produce control limits for the proportions. During this initial phase, the process
should be in control. If points are out-of-control during the initial (estimation) phase, the assignable cause
should be determined and the sample should be removed from estimation. Once the control limits have been
established for the P chart, these limits may be used to monitor the proportion nonconforming of the process
going forward. When a point is outside these established control limits it indicates that the proportion
nonconforming of the process is out-of-control. An assignable cause
is suspected whenever the control chart indicates an out-of-
control process.

̅
(NOTE:- ALL DIEMENSIONS ARE IN MM)
Observation Table

S. no. Inspected (n) Defected P

1 10
2 9
3 7
4 11
5 8
6 9
7 10
8 9
2 0.2
0 0
1 0.143
1 0.09
0 0
1 0.11
2 0.2
0 0

15
 9 11 1 0.09
10 7 1 0.143
11 9 1 0.11
n̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 9.09 p̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 0.0987

LCL = 0 AND UCL = 0.395

P-Chart
0.45

0.4

0.35

0.3
P
0.25
LCL
0.2 CL
0.15 UCL

0.1

0.05

0
1 2 3 4 5 6 7 8 9 10 11

EXPERIMENT :-4

AIM:- To construct a NP chart(is a zoom chart of P)

Theory
This procedure generates the NP control chart for the number nonconforming of a sample. The format of the
control charts is fully customizable. This procedure permits the defining of stages. For the NP chart, the value for
P can be entered directly or NP can be estimated from the data, or a sub-set of the data. A list of out-of-control
points can be produced in the output, if desired, and proportion nonconforming values may be stored to the
spreadsheet. NP Control Charts NP charts are used to monitor the number of nonconforming units of a process
based on samples taken from the process at given times (hours, shifts, days, weeks, months, etc.). Typically, an
initial series of samples is used to estimate the average number of nonconforming units per sample. The estimated
average is then used to produce control limits for the number of nonconforming units. During this initial phase,
the process should be in control. If points are out-of-control during the initial (estimation) phase, the assignable

16
cause should be determined and the sample should be removed from estimation. Once the control limits have been
established for the NP chart, these limits may be used to monitor the number nonconforming going forward.
When a point is outside these established control limits it indicates that the number of nonconforming units of the
process is out-of-control. An assignable cause is suspected whenever the control chart indicates an out-of-control
process.

𝑛
(NOTE:- ALL DIEMENSIONS ARE IN MM) Observation
Table

Sample no. Inspected (n) defective (np)

1 10 1
2 10 0
3 10 2
4 10 0

5 10 1
6 10 1

7 10 0
8 10 2

9 10 1
10 10 2
np̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 1

LCL = 0 mm AND UCL = 3.98 mm

17
 np-Chart
4.5

3.5

3
np
2.5
LCL
2 CL
1.5 UCL

0.5

0
1 2 3 4 5 6 7 8 9 10

18
 EXPERIMENT :- 5

AIM : To construct c -chart of the quality characteristics of a given set of components Theory
This procedure generates the C control chart for the number of nonconformities (defects) on a unit. The format of
the control chart is fully customizable. This procedure permits the defining of stages. For the C chart, the value for
C (the average number of nonconformities) can be entered directly or estimated from the data, or a sub-set of the
data. A list of out-of-control points can be produced in the output, if desired. C Control Charts C charts are used to
monitor the number of nonconformities on a unit of a process based on units taken from the process at given times
(hours, shifts, days, weeks, months, etc.). Typically, an initial series of units is used to estimate the average
number of nonconformities of a process. The estimated value is then used to produce control limits for the number
of nonconformities. During this initial phase, the process should be in control. If points are out-ofcontrol during
the initial (estimation) phase, the assignable cause should be determined and the unit should be removed from
estimation. Once the control limits have been established for the C chart, these limits may be used to monitor the
number of nonconformities (defects) of the process going forward. When a point is outside these established
control limits it indicates that the number of nonconformities for a unit of the process is out-ofcontrol. An
assignable cause is suspected whenever the control chart indicates an out-of-control process.

𝑈𝐶𝐿 = 𝐶 + 3√𝐶̅

𝐿𝐶𝐿 = 𝐶 − 3√𝐶̅

(NOTE:- ALL DIEMENSIONS ARE IN MM)

OBSERVATION TABLE :-
Sample no. Defect (C) 16 1
1 1 17 0
2 1 18 0
3 1 19 0
4 0 20 0
5 1 21 2
6 0 22 0
7 0
23 1

8 0
24 0

9 1
25 1
10 1 26 1
11 1
27 0

19
12 0
28 1

13 1
29 1

14 1
30 0

15 0
31 0

20
32 1 68 0
33 0 69 0
34 1 70 0
35 0 71 0
36 0 72 1
37 0 73 0
38 0 74 0
39 0 75 1
40 1 76 0
41 0 77 0
42 0 78 0
43 0 79 0
44 0 80 1
45 0 81 1
46 1 82 0
47 0 83 0
48 0 84 0
49 0 85 0
50 1 86 0
51 0 87 0
52 0 88 0
53 0 89 0
54 0 90 0
55 0 91 0
56 1 92 1
57 0 93 0
58 0 94 1
59 0 95 0
60 0 96 0
61 1 97 1
62 1 98 0
63 0 99 0
64 0 100 1
65 0 C-Bar= 0.34
66 1
67 0

21
 LCL = 0 mm AND UCL =2.09 mm

C-Chart
2.5

Series1
1.5
Series2
1 Series3
Series4
0.5

Series 1 = Defective Value Series 2 = UCL

Series 3 = CL (Mean Value) Series 4 = LCL

22
 EXPERIMENT:-6
Aim : To construct a operating characteristics (OC) curve
.
Theory : The operating characteristic curve for an attribute sampling plan is a graph of fraction defective
in a lot against the probability of acceptance. For any fraction defect p in a submitted lot, the oc curve shows
the probability acceptance Pa that such a lot will be accepted by the sampling plan. In a single sampling
plan three parameters are specified.
N = lot size from which the samples are drawn.
n = sample size C = acceptance number
𝜆 = Poisson’s ratio

(NOTE:- ALL DIEMENSIONS ARE IN MM)

Observation Table

Accept Defect
ance N s (D) P N P(a)th. 1 2 3 4 5 P(a)act.
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.986 1 0 0 0 0 0.8
C=2 100 2 0.02 20 0.4 0.983 0 0 1 0 1 0.6
100 3 0.03 20 0.6 0.962 0 0 1 0 2 0.6
100 4 0.04 20 0.8 0.935 0 2 0 1 1 0.4
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.987 0 0 1 0 0 0.8
C=3 100 2 0.02 20 0.4 0.99 0 0 1 1 0 0.6
100 3 0.03 20 0.6 0.981 0 1 2 0 0 0.6
100 4 0.04 20 0.8 0.973 0 1 1 1 1 0.2
100 0 0 20 0 1 0 0 0 0 0 1
100 1 0.01 20 0.2 0.987 0 0 1 0 0 0.8

23
C=4 100 2 0.02 20 0.4 0.99 0 0 2 0 0 0.8
100 3 0.03 20 0.6 0.983 1 0 1 1 0 0.4
100 4 0.04 20 0.8 0.98 1 0 1 1 1 0.2

C=2
1.2
1
0.8
0.6
0.4
0.2
0
0 1 2 3 4
Defective

P(a)th. P(a)act.

C=3
1.2
1
0.8
0.6
0.4
0.2
0
0 1 2 3 4
Defective

P(a)th. P(a)act.

24
 C=4
1.2
1
0.8
0.6
0.4
0.2
0
0 1 2 3 4
Defective

P(a)th. P(a)act.

Conclusion : 1. As the acceptance no. increases the theoretical pa tends to become

straight.
2. As the acceptance no. increases the actual pa line tends to bend.

CHAPTER-3 Conclusion Of Project

25
EXPERIMENT 1
FOR DIAMETERS:-
• The mean value of the data is 11.42 mm.
• The median is 11.5 mm.
• The mode value of the database is 11 mm.
• The value of standard deviation is found to 0.898146 mm.
• And the variance is 0.8067 mm.
FOR THICKNESS:-
• The mean value of the data is 1.665 mm. The median is 2 mm.
• The mode value of the database is 1 mm.
• The value of standard deviation is found to 0.73187 mm. And the variance is 0.53563 mm.

Merits
• We can easily find out the value of mean
• The mode is also find out by calculating the most repeated data.
• Deviation tells that the data we have assumed is suitable for production process or not.
Demerits
• The calculation process for standard deviation is too much lengthy.

EXPERIMENT 2
X bar and R chart
• UCLẊ is 12.40 mm
• LCLẊ is 10.44 mm.
• UCLR is 3.59 mm.
• LCLR is 0 mm

Merits
• The X bar and R chart is used for variable data.
• Ẋ bar chart is important for the measurement of central tendency.
• Ẋ and R chart when used together form a powerful instrument for diagnosing quality problems.
• The two control units tells whether the quality of a product is in control or not.

Demerits
A control chart sometimes may indicate that a process is out of control and that there is special
cause variation where none exists.These false alarms can cause unnecessary downtime and delays
which can lost a business money.

26
EXPERIMENT 3
P- chart
• Ṗ for the data is 0.0987 mm
• UCLp from the observation is 0.395 mm
• LCLp from the calculation is 0 mm

Merits
• In P control chart each item is specified as good (non defective) or bad (defective).
• The sample size for the p chart can be a variable.
• This chart is used to control the general quality of the component parts.
• It checks if the fluctuation in a product quality is due to chance cause alone.

Demerits
Control chart is one kind of the most common and effective tool for statistical quality control
however this is not infallible forever. The result of actual data processing have proved that the
conventional chart may educe the opposite conclusion to other evaluating method in some special
cases.

EXPERIMENT 4
NP chart

• The value of UCLnp is 3.98 mm The value of LCLnp is 0.

• The control limit or np bar is 1 mm.
• The values does not cross the ucl.

Merits
• In statistical quality control the np chart is a type control chart used to monitor the number of non
conforming units in a sample.
• The samle size is always constant.

Demerits
No demerits are found in this chart because the sample size is taken constant. And the values can be
calculated easily.

EXPERIMENT 5
C-chart
• The UCLC from the calculation is 2.09 mm LCLC is found to
be 0 mm.
• The control limit or C bar is 0.34 mm.

Merits
• In this method of quality checking we determine the defect of a single part or piece.

27
 • It is preferred for large and complex parts.
• This chart is used where average number of defects are much less than the number of defects which
would occur otherwise if everything possible goes wrong.

Demerits

The demerits too much less than the merits because here we inspect defect in a single part or
component .

EXPERIMENT 6
Operating characteristics (OC) curve

• As the acceptance number increases the theoretical pa line will tend to become straight.
• As the acceptance number increases the actual pa line will tend to bend.
• The movement of the pa theoretical line is slow in comparison of the pa actual line .
• This curve is working on the situation of customer and producer’s risk. As the lot is selected and
there are more defect than the sample size so it will be the customer’s risk and if the lot is rejected
and there were all the defects all presented in the sample and no defects in the lot so it will be the
producer’s risk.

In my opinion the NP chart and the C charts are the best charts than the other charts because in NP charts
the sample size is always constant and in the c charts, we have to examine the defect in single part or piece
but it should done where the tolerance of the parts are to be tight and the part have to done some precious or
special work.

Comparison between Attribute Charts and Variable Charts

Variable Charts Attribute Charts

1. Example: ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ Example: P, nP, C Charts
2. Type of Data Required
Variable data ( Measured value of Attribute data (using Go-No-Go gauges)
characteristics)
3. Field of Application
Control of individual characteristics. Control of proportion of defective or
number of defects or number of defects per
unit.
4. Advantages

28
 Provides maximum utilisation of
information available for data.
Provide detailed information on
process average and variation for
control of individual dimensions.
5.
They are not easily understood
unless training is provided.
Can cause confusion between
control limits and specification
limits.
Cannot be used with go-no-go type
gauge inspection.
Data required are often already
available from inspection records.
Easily understood by all persons. Since,
it is more simple as compared to X ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ and
R chart.
It provides over all picture of quality
history.
Disadvantages
They do not provide detailed
information for control of individual
characteristics.
They do not recognize different
degree of defectiveness.
(Weightage of defects)

Which Charts are better for which data or plan?

For Variable data

For variable data generally ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ Chart and R chart are used for the examination of data. But the ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ chart is
most widely used in all type of industries to put an eye on the production i.e., the product is under tolerance
value or not. The ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ chart is good for variable data because it concludes all the variable values like Range,
Standard deviation and much more.

For Attribute data

For attribute data P chart, np Chart and C chart are widely used but the best chart used is P chart due to its
acceptability.

The P chart can be used anywhere, where data is discrete. It can be used for same sample group size as well
as different sample group size. That’s why, P chart is most widely used for controlling the defects in an
industry.

Acceptance Sampling Plan

For acceptance sampling plan the OC Curve is best suited method to check the defects and to calculate
different parameters like Producer Risk, Consumer Risk, Total outgoing Quality Level and much more.

29
Due to its simple ness and easy to read it can be concluded that it is the best method to observe the defects
occurring in a single product.

30
CHAPTER – 4 REFRENCES
• https://www.google.co.in/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=
0ahUKEwib24bLvOTWAhUCUI8KHUwBCbsQjRwIBw&url=http%3A%2F%2Fwww.bakerross.co.
uk%2Fgro-szlig-packung-plastikkn-ouml-
pfe&psig=AOvVaw2nhw1a9jd2VvxpgGCbcJHx&ust=1507670501829452

• Laboratory File.
• Data sample from Buttons.
26