Unit 1 Introduction

2 lecture hours

• definition of quality
• basic concept of quality
• definition of SQC, benefits and limitation of SQC, Quality assurance
• Quality cost

Unit 2 Process Control for Variables and Attributes

8 lecture hours

• Causes of Variation
• Control Charts for Variables (Mean and Range
• Mean and Standard Deviation
• Cumulative Sum Control Chart)
• Control Chart Patterns and Corrective Actions
• Control Charts for Attributes (p-chart
• Acceptance Sampling Plans (Concepts of Producer’s and Consumer’s Risks
• Types of Sampling Plans and their merits and demerits
• Operating Characteristic Curve
• Average Outgoing Quality Curve)
• Errors in Making Inferences from Control Charts (Type I and II errors)

Unit 3 Designing for Quality

5 lecture hours

• Introduction to Concurrent Engineering
• Quality Function Deployment (QFD) and Failure Mode and Effect Analysis (FMEA) – Concept
• Methodology and Application

Unit 4 Six Sigma Fundamentals

6 lecture hours

• Basic Concept
• Process Improvement Model (DMAIC) Steps (Objectives
• Tools and Techniques Used)
• Six Sigma Organization
• Six Sigma Implementation Requirements
• Introduction to Lean Manufacturing

Unit 5 Reliability Engineering

• 10 20% Reliability function
• failure rate
• Mean time between failures (MTBF)
• Mean time to failure (MTTF)
• mortality curve
• useful life availability
• system effectiveness
• Introduction to probability distributions
• Time to failure distributions: Exponential
• ranking of data
• probability plotting techniques
• Hazard plotting Concept of Bathtub Hazard Rate curve
• Reliability evaluation of two-state device networks-series
• k-out-of-m systems
• Standby redundant systems
• Reliability evaluation of three- state device networks-series and parallel

Unit 6 Reliability Determination and Prediction

10 lecture hours

• Reliability Determination Methods: Network reduction technique
• Path tracing technique
• Decomposition technique
• Delta-Star method
• Advanced Reliability Evaluation Concepts: Supplementary variables technique
• Interference theory
• Human reliability
• Common cause failures
• Fault trees
• Failure mode and effect analysis
• Reliability Prediction Models: Series and parallel systems - RBD approach - Standby systems - m/n configuration - Application of Baye's theorem - cut and tie set method - Markov analysis - FTA - Limitations

Unit 7 Reliability Management

8 lecture hours

• Reliability testing: Time acceleration factor
• influence of acceleration factor in test planning
• application to acceleration test
• high temperature operating life acceleration model
• temperature humidity bias acceleration model
• temperature cycle acceleration model
• vibration accelerator model
• failure free accelerated test planning
• Accelerated reliability growth

Unit 8 Risk Assessment

3 lecture hours

• Definition and measurement of risk - risk analysis techniques - risk reduction resources - industrial safety and risk assessment
• References Books: 1
• Grant E L, Statistical Quality Control“
• Shrinath L S, Reliability Engineering” Affiliated East west press. 3
• Besterfield D H, Quality Control
• Prentice Hall. 4
• Sharma S C, Inspection Quality Control and Reliability
• Khanna Publishers. 5
• Practical Reliability Engineering”
• John Wiley. 6
• Naikan V N A Reliability Engineering and Life Testing”
• PHI Learning Private Limited. 7
• Prabhakar Murthy D N and Marvin R, “Product Reliability”
• Dana Crowe and Alec Feinberg
• Design for Reliability
• CRC Press

Unit 9 John W Priest and Jose M Sanchez, “Product Development and Design for Manufacturing –

• A Collaborative Approach to Producibility and Reliability”
• Second Edition
• Marcel Dekker