3rd Edition

Acceptance Sampling in Quality Control

    882 Pages 160 B/W Illustrations
    by Chapman & Hall

    882 Pages 160 B/W Illustrations
    by Chapman & Hall

    Acceptance Sampling in Quality Control, Third Edition presents the state of the art in the methodology of sampling while integrating both theory and best practices. It discusses various standards, including those from the ISO, MIL-STD and ASTM and explores how to set quality levels. The book also includes problems at the end of each chapter with solutions. This edition improves upon the previous editions especially in the areas of software applications and compliance sampling plans.

    New to the Third Edition:

    • Numerous Microsoft Excel templates to address sampling plans are used.
    • Commercial software applications are discussed at the end of many chapters.
    • Discussion of quick switching systems has been expanded to account for the considerable recent activity in this area.
    • Added discussion of zero acceptance number chained quick switching systems.

     

     

    1 INTRODUCTION

    Acceptance Quality Control

    Acceptance Control and Process Control

    Process Quality Control

    Background of Acceptance Quality Control

    Top Ten Reasons for Acceptance Sampling

    References

    Problems

    2 PROBABILITY AND THE OPERATING CHARACTERISTIC CURVE

    Probability

    Classical Definition

    Empirical Definition

    Subjective Definition

    Random Samples and Random Numbers

    Counting Possibilities

    Probability Calculus

    The Operating Characteristic Curve

    Software Applications

    Excel

    Minitab

    References

    Problems

    3 PROBABILITY FUNCTIONS

    Probability Distributions

    Measures of Distribution Functions

    Hypergeometric Distribution

    Binomial Distribution

    Poisson Distribution

    f-Binomial Distribution

    Negative Binomial Distribution

    Exponential and Continuous Distributions

    Weibull Distribution

    Normal Distribution

    Summary of Distributions

    Tables of Distributions

    Hypergeometric Tables

    Binomial Tables

    Poisson Tables

    Negative Binomial Tables

    Normal Distribution Tables

    Summary

    Useful Approximations

    Tests of Fit

    Software Applications

    Excel

    Minitab

    References

    Problems

    4 CONCEPTS AND TERMINOLOGY

    Average Run Length of Type B Plans

    Samples Size and Lot Size

    Effect of Inspection Error

    Rectification

    Curtailment

    Tolerance and Confidence Intervals

    Levels and Risks

    Choosing Quality Levels

    Classification of Defects

    Measures of Sampling Plans: Terminology

    Graphs of Measures

    Specifying a Plan

    Software Applications

    Minitab

    References

    Problems

    5 SINGLE SAMPLING BY ATTRIBUTES

    Operation

    Selection

    Table of Poisson Unity Values

    Binomial Nomograph

    f- Binomial Nomograph

    Thorndyke Chart

    Hypergeometric Tables

    Measures

    Software Applications

    Excel

    Minitab

    Statgraphics

    References

    Problems

    6 DOUBLE AND MULTIPLE SAMPLING BY ATTRIBUTES

    Operation

    Double Sampling

    Multiple Sampling

    Selection

    Measures

    Double Sampling

    Multiple Sampling

    Further Considerations

    Software Applications

    Excel

    Minitab

    Statgraphics

    References

    Problems

    7 SEQUENTIAL SAMPLING BY ATTRIBUTES

    Operation

    Selection

    Measures

    Sequential Sampling for Defects per Unit

    Software Applications

    Excel

    References

    Problems

    8 VARIABLES SAMPLING FOR PROCESS PARAMETER

    Single Sampling for Process Parameter

    Acceptance Control Charts

    Sequential Plans for Process Parameter ( Known)

    Sequential Plans for Process Parameter ( Unknown)

    Cumulative Sum Charts

    References

    Problems

    9 BULK SAMPLING

    Construction of the Sample

    Estimation

    Sampling Plans

    Simple Random Sampling of Unique Lot (Components of Variance Unknown)

    Sampling from Stream of Lots

    Estimation of Testing and Reduction Variances

    Estimation of Segment and Increment Variances

    Application of Plan to Stream of Lots

    References

    Problems

    10 SAMPLING BY VARIABLES FOR PROPORTION NONCONFORMING

    Specification Limits

    Assumptions and Theory

    Operation

    Method

    k Method

    Double Specification Limits

    Selection

    Tables

    Formulas

    Jacobson Nomograph for Plan Selection

    Measures

    Jacobson Nomograph for Operating Characteristics

    Calculation:  Known

    Calculation:  Unknown

    Double Specification Limits

    Measures of Performance

    M Method

    Plans Based on Sample Range

    Double Sampling by Variables

    Tolerance Intervals and Variables Plans for Percent Nonconforming

    Sequential Plans for Proportion Nonconforming

    Further Considerations

    Derivation of n, k Formulas

    Need for Normality

    Software Applications

    Minitab

    Statgraphics

    References

    Problems

    11 ATTRIBUTES SAMPLING SCHEMES

    Sampling Schemes

    Quick Switching Systems

    TNT Plans

    Mil-Std-105E and Derivative Standards

    Operation

    Selection

    Measures

    Scheme Properties

    Implementation of MIL-STD-105E

    Matching Individual Sampling Plans to MIL-STD-105E System Performance

    MIL-STD-105 Derivatives

    Further Considerations

    Software Applications

    Minitab

    Snap Sampling Plans!

    Statgraphics

    References

    Problems

    12 VARIABLES SAMPLING SCHEMES

    Mil-Std-414

    Operation

    Selection

    Measures

    Implementation of Form 2

    Implementation of Form 1

    Implementation of Plans for Range and Variability Known

    Match Between MIL-STD-414 and MIL-STD-105E

    Conversion of MIL-STD-414 to ANSI/ASQ Z1.9

    MIL-STD-414 Derivatives

    Further Considerations

    Software Applications

    Excel

    Minitab

    Statgraphics

    References

    Problems

    13 SPECIAL PLANS AND PROCEDURES

    No-Calc Plans

    Lot Plot Plans

    Narrow Limit Gauging

    Mixed Variables - Attributes Plan

    Advantages and Disadvantages of Mixed Plans

    Generalized Mixed Dependent Procedure

    Measures: Independent Mixed Plan

    Measures: Dependent Mixed Plan

    Mil-Std-414 Dependent Mixed Plans

    Comparison of Independent and Dependent Mixed Plans

    Comparison of Mixed and Other Type Plans

    References

    Problems

    14 SERIES OF LOTS: RECTIFICATION SCHEMES

    Single-Sampling AOQL Plan

    Dodge-Romig Sampling Scheme

    Operation

    Selection

    Measures

    Further Considerations

    Constructing LTPD Plan With Minimum ATI

    Constructing AOQL Plan With Minimum ATI

    Anscombe Rectifying Inspection Procedure

    Operation

    Selection

    Measures

    Credit-Based Schemes

    Dodge-Romig Plan Derivatives

    Software Applications

    Excel

    Snap Sampling Plans!

    References

    Problems

    15 CONTINUOUS SAMPLING PLANS

    Dodge Continuous Plans

    Dodge CSP-1

    Dodge-Torrey CSP-2 and CSP-3

    Measures of CSP-1, 2, 3

    Stopping Rules and Selection of CSP-1 Plans

    Multi-Level Plans

    Tightened Multi-Level Plans

    Block Continuous Plans

    Wald-Wolfowitz Plan

    Girshick Plan

    MIL-STD-1235B

    MIL-STD-1235B Derivatives

    Software Applications

    Excel

    Snap Sampling Plans!

    References

    Problems

    16 CUMULATIVE RESULTS PLANS

    Skip-Lot Sampling Plans

    SkSP-1

    SkSP-2

    Chain Sampling Plans

    ChSP-1

    Two-Stage Plans

    Deferred Sentencing Schemes

    Demerit Rating Plan

    Cumulative Results Criterion Plan (CRC)

    Software Applications

    Excel

    References

    Problems

    17 COMPLIANCE SAMPLING

    Lot Sensitive Sampling Plan (LSP)

    Procedure

    Protection

    Producer’s Risk

    Examples of LSP Applications

    Further Considerations

    Tightened-Normal-Tightened (TNT) Scheme

    Procedure

    Protection

    Selection

    Quick Switching System (QSS)

    Mil-Std-1916

    Structure

    Operation

    Implementation

    Measures

    Further Considerations

    Simplified Grand Lot Procedure

    Simon’s Approach

    Simplified Procedure: Attributes

    Simplified Procedure: Variables

    Continuing Series of Lots

    Further Considerations

    Accept on Zero (AoZ) Plans

    U. S. Department of Defense Approach

    Squeglia Plans

    AOZ and AQL Plans

    Chain Sampling Alternative

    The Zero Acceptance Number Chained Quick Switching System

    Summary

    Software Applications

    Excel

    LSP Plans

    TNT Plans

    QSS Plans

    MIL-STD-1916 Plans

    Chain Sampling Alternative Plans

    Zero Acceptance Number Chained Quick Switching System Plans

    Minitab

    Snap Sampling Plans!

    LSP Plans

    Squeglia Plans

    Statgraphics

    MIL-STD-1916 Plans

    References

    Problems

    18 RELIABILITY SAMPLING

    Censored Sampling

    Variables Plans for Life Testing and Reliability

    Handbook H-108

    Operation

    Failure Terminated

    Time Terminated

    Sequential

    Proportion Failing by Specified Time

    Selection

    Example of H-108 Application

    Failure Terminated

    Time Terminated

    Sequential

    Proportion of Lot Failing by Specified Time

    Measures

    Further Considerations

    Technical Report TR 7

    Mean Life Criterion

    Hazard Rate Criterion

    Reliable Life Criterion

    TR 7 Tables

    Operation

    TR 7 with the Mil-Std-105E System

    Further Considerations

    References

    Problems

    19 ADMINISTRATION OF ACCEPTANCE SAMPLING

    Selection and Implementation of a Sampling Procedure

    Determining Quality Levels

    Setting AQL

    Setting AOQL

    Setting IQ

    Setting LTPD (or LQ)

    Relation of Levels

    Setting PQL and CQL

    Economic Considerations

    Mandatory Standards

    Basic Principle of Administration

    References

    Problems

    APPENDIX TABLES

    ANSWERS TO PROBLEMS

    AUTHOR INDEX

    SUBJECT INDEX

    Biography

    Dr. Edward G. Schilling was a professor emeritus of statistics at the Center for Quality and Applied Statistics, at Rochester Institute of Technology (RIT), where he had been the director of the center and the chair of the Graduate Statistics Department.

    Before joining RIT, he was the manager of the lighting quality operation for the Lighting Business Group of General Electric Company. He received his BA and MBA from State University of New York (SUNY) at Buffalo, and his MS and PhD in statistics from Rutgers University. He had been on the faculties of SUNY at Buffalo, Rutgers University, and Case Western Reserve University. He had extensive industrial experience in quality engineering at Radio Corporation of America (RCA) and the Carborundum Co., and in statistical consulting and quality management at General Electric. Dr. Schilling was a fellow of the American Society for Quality (ASQ), the American Statistical Association (ASA), and the American Society for Testing and Materials (ASTM). He was also a member of the Institute of Mathematical Statistics and the American Economic Association. He was registered as a professional engineer in California and certified by ASQ as a quality and a reliability engineer. He served as the founding series editor for the Marcel Dekker series of books on quality and reliability, and published extensively in the field of quality
    control and statistics.

    Dr. Schilling was the Shewhart Medalist in 1983, the recipient of the E.L. Grant Award in 1999, the Freund–Marquardt Medal in 2005, and the Distinguished Service Medal in 2002; he was the first person to receive the Brumbaugh Award four times from the ASQ. He was also the recipient of the Ellis R. Ott Award in 1984 for his contributions to quality management from the Metropolitan New York Section of that society and was honored by being invited to present the 1986 W.J. Youden Memorial Address at the Joint ASQ/ASA Annual Fall Technical Conference. He was the recipient of the H.F. Dodge Award by the ASTM in 1993 and the Award of Merit in 2002.

    Dr. Schilling was an associate editor of the fifth edition of Juran’s Quality Control Handbook.  His book, Process Quality Control (with E.R. Ott and D.V. Neubauer), is among the leading texts in the field.

     

    Dean V. Neubauer is an Engineering Fellow in the Process Engineering Directorate in the Manufacturing, Technology and Engineering (MTE) Division at Corning Incorporated.  He has worked for Corning since 1981 and has been involved in projects in every major business over this time. He has fifteen U.S. patents for compositional work on a variety of materials and devices for the manufacture of display glass.  His background includes degrees in statistics from Iowa State University and Rochester Institute of Technology.

    Outside of Corning, Dean has taught as an Adjunct Professor in the M.S. program for the Center for Quality and Applied Statistics at R.I.T. since 1992.  He also participates on the ASTM E-11 Committee on Quality and Statistics where he is a Past Chairman and is a member of the ASTM International Committee on Standards (COS).  Dean is a book reviewer for the Technometrics and Journal of Quality Technology journals, serves on the Management Committee of the Technometrics journal, serves on the Editorial Board of the Quality Engineering journal, is the co-author of Process Quality Control, 4th Edition with the late Dr. Edward G. Schilling.  He is also a former U.S. Lead Delegate to the ISO Technical Committee 69 on Statistical Methods Subcommittee SC5 on Acceptance Sampling.  In this role, he was responsible for the review of ISO, as well as, ANSI/ASQ Z acceptance sampling standards.

    Dean was elected a Fellow of the American Society for Quality (ASQ) in 2000 and is a Certified Quality Engineer. Dean is also a Past Chair of the ASQ’s Chemical and Process Industries Division and a Past Chair of the Corning-Elmira ASQ Section.  He is a recipient of the 2003 Shewell Award from ASQ and the 2011 Harold F. Dodge Award from ASTM.  He has also been a Member of the American Statistical Association since 1979 and is an accredited professional statistician (PStat™).  In 1993, he was elected a Fellow of the Royal Statistical Society in London, England and holds the certification of Chartered Statistician (CStat).  In 2010, he was given the Award of Merit carrying the title of Fellow from the American Society for Testing Materials (ASTM).

    Praise for the Second Edition:

    … a very well-presented book, covering the classic topics of inspection sampling in a thorough, lucid and insightful way. … [It] is an elegant and comprehensive resource for the knowledgeable user, and so well written that the beginner will also find it congenial and rewarding…
    John Shade, Journal of the Royal Statistical Society

    [The] first edition of Acceptance Sampling in Quality Control is a classic, and is considered by many as a "must have book" for anyone working in quality control. … With the current expectations of continuous improvement, [and] rigorous process control …some may tend to think that acceptance sampling is not as important as it was in the past. However, with a world economy and ever improving technology, the relationship between customers and suppliers has changed dramatically with distance, cultures, and language all having an impact. This makes acceptance sampling as important as ever and this book as relevant as ever.
    Theresa L. Utlaut, Journal of Quality Technology