1. Unit 8 Measurement and Quality
Chapter 19 -Quality Assurance and Control

2. Quality Assurance and Control-
Quality Assurance maintains Product Quality
Source Inspection before Manufacturing
In-process Quality Control during Manufacturing
Product Service and Warranties after production

3. Quality assurance-
All activities in manufacturing are directed toward ensuring production of a high-quality product.

4. Quality control-
One segment of quality assurance often responsible for dimensional inspection (among others) during production.

5. Source Inspection before Manufacturing
Source of materials, parts, subassemblies
Sort out/reject poor quality material at the source
Visual Inspection – color, texture, surface finish, appearance
Metallurgical Testing – hardness, tensile strength, etc.
Dimensional Inspection – measuring tools/gages
Destructive/Nondestructive Testing – stress/xrays
Performance Inspection – testing engines, etc.

6. In-process Quality Control during Manufacturing
Same checks as with Source Inspection
Sort out/reject poor quality parts/products
Receiving Inspection – parts/matls coming in
1st Piece Inspection – after retooling; 1st part off the line is inspected before production begins
In-process Inspection – machine operator/ assembler inspects
100% Inspection – often used for critical parts; too expensive for high-volume production
Final Inspection – last chance

7. Non-dimensional Quality Control
Measure Power Output
Measure Radiation Output
Microwave, radio emissions, interference

8. Product Service and Warranties after production
Guaranty of product performance after purchase
Warranty
A guarantee of product quality provided by the manufacturer promising parts, service, or replacement in the case of a product failure.

9. Product Testing
Prototype Stage
Controlled Markets
Endurance Testing

10. Lean is centered on preserving value with less work.
Lean Manufacturing
Lean manufacturing or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.
Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for.
Lean is centered on preserving value with less work.

11. Lean Manufacturing

12. Unit 8 Measurement and Quality
Chapter 20-Inspection and Measurement

13. Inspection and Measurement-
Why Measure a Product? >
Out of Spec Product =
Wasted production costs
Product failure or non-function
Liability for consequences
How a Product is Measured
Visual Inspection
Comparison Inspection
Measurement

14. Measurement standards-
Known standards to which production gages and other measurement tools are periodically compared to ensure their conformity and accuracy.
Gage blocks are an example.

15. Fixed gages-
Instruments used for comparison inspection that do not display a reading.

16. Inspection- Inspection Instruments (Inspection)
Plugs, rings, templates
Steel rules, protractors
Micrometers, height gages, coordinate measuring machines
Size Specifications and Locations (Meas.)
Form Specifications (Meas.) (Fig
Perpendicularity, squareness, flatness, straightness, concentricity, etc.

17. Comparison Inspection-
Fixed Gages (Fig. 20.5, .6, .7, .8)
Compare part to gage of correct spec.
“GO/NO GO” gages (do not display a reading)
Screw-pitch gages and Radius Gages (Fig & .10)
Worker simply compares, no reading or interpreting data 
Many different gages required 

18. Measurement, Precision, and Resolution-
Things affecting Measurement Precision of Instrument
Resolution
Reliability and Repeatability
Condition of Surfaces of Workpiece
Worker Skill
Temperature and other environmental factors

19. Precision- Repeatability No larger than 1/10 of the tolerance range
The amount of size variation (range variation) in the component or product features created by a manufacturing process.
No larger than 1/10 of the tolerance range
Tolerance range = 0.010, then
Instrument precision = 0.001

20. Resolution-
Smallest deviation the instrument can detect.

21. Measuring Tools- Direct Reading Instruments (fig.s 20.13- .23)
Micrometers, calipers, etc. - measure whole distance (examine Calipers)
Deviation-type gages (fig.s )
Measure only deviation from master
Transfer-type instruments
Telescoping hole gages (fig )

22. Vernier scale-
An added scale that improves the resolution of micrometers and other precision measuring instruments
mechanically magnifies tiny variations in a dimension.

23. Measuring Tools- Semiprecision Tools
Steel rule – 1/64” accuracy (Fig. 2.12)
Combination set (Fig )
Thickness gage (Fig )
Rule-depth gage (Fig )

24. Calibration-
The processes of comparing measuring instruments and gages against known measurement standards and then adjusting them to conform with the standards.

25. CMM Coordinate measuring machine
a computerized measuring instrument that precisely tracks the movement of a probe in three-dimensional space.
The CMM records the location of the probe as it touches the workpiece, making the CMM useful for measurement of size, form, and location.

26. Surface finish (surface roughness)-
A form specification that determines the smoothness of the minute peaks and valleys that compose a machined surface.

27. Temperature Effects
Temperature changes cause metals to expand and contract – this affects the accuracy of measurements
Standard measuring temperature is 68º F

28. Interchangeability-
The concept that parts manufactured by many different manufacturers to the same dimensional specifications may be interchanged in assemblies.
Different parts of same assembly may come from different manufacturers

29. Standards- Master Measurement Standards Maintained by NIST
National Institute of Standards and Technology (formerly NSB – National Bureau of Standards)

30. Summary- Products must be Measured to ensure proper size and form
Measuring Tools used must allow repeatable and accurate measurements
Measuring tools may be direct-reading or “Go/No Go”
“Go/No Go” measuring tools allow for faster and more accurate comparisons
Direct reading instruments produce a readout – can be slow and can be misread
“Go-No Go” instruments do not produce a readout but can be used more quickly than Direct reading instruments
Semiprecision Measuring Tools rely on average eyesight to achieve reasonable accuracy

31. Summary-
Temperature changes cause metals to expand and contract – this affects the accuracy of measurements
Standard measuring temperature is 68º F
Interchangeability – parts manufactured by many different manufacturers to the same dimensional specifications may be interchanged in assemblies.

32. Measuring with Dial Calipers
Introduction to Basic Statistics
Introduction to Engineering Design TM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Measuring with Dial Calipers

33. Dial Calipers Dial Calipers Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
At the conclusion of this presentation, you will be able to…
identify four types of measurements that dial calipers can perform.
identify the different parts of a dial caliper.
accurately read an inch dial caliper.
Project Lead The Way, Inc.
Copyright 2007

34. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Dial Calipers are arguably the most common and versatile of all the precision measuring tools used by engineers and manufacturers.
Regardless of what type of caliper you use, be sure to take the following precautions to avoid damaging the caliper:
1. Wash your hands before you handle the dial caliper to remove dirt and oils that might damage the caliper.
2. Wipe the caliper components clean both before and after you use the caliper.
3. Do NOT drop or otherwise mishandle the caliper. Doing so may damage or destroy the caliper.
Project Lead The Way, Inc.
Copyright 2007

35. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Dial calipers are used to perform four common measurements on parts…
Outside Diameter or Object Thickness
Inside Diameter or Space Width
Step Distance
Hole Depth
Project Lead The Way, Inc.
Copyright 2007

36. Outside Measuring Faces
Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Outside Measuring Faces
These are the faces between which outside length or diameter is measured.
Project Lead The Way, Inc.
Copyright 2007

37. Dial Calipers Example: Outside Diameter of object Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Example: Outside Diameter of object
Project Lead The Way, Inc.
Copyright 2007

38. Inside Measuring Faces
Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Inside Measuring Faces
These are the faces between which inside diameter or space width (i.e., slot width) is measured.
Project Lead The Way, Inc.
Copyright 2007

39. Dial Calipers Example: Inside measuring Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Example: Inside measuring
Project Lead The Way, Inc.
Copyright 2007

40. Step Measuring Faces Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Step Measuring Faces
These are the faces between which stepped parallel surface distance can be measured.
Project Lead The Way, Inc.
Copyright 2007

41. Dial Calipers Example: Step Distance Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Example: Step Distance
Project Lead The Way, Inc.
Copyright 2007

42. Depth Measuring Faces Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Depth Measuring Faces
These are the faces between which the depth of a hole can be measured.
Project Lead The Way, Inc.
Copyright 2007

43. Dial Calipers Example: Depth Measuring
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Example: Depth Measuring
Note: Work piece is shown in section. Dial Caliper shortened for graphic purposes.
Project Lead The Way, Inc.
Copyright 2007

44. Dial Calipers Nomenclature Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Nomenclature
Project Lead The Way, Inc.
Copyright 2007

45. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
A standard inch dial caliper will measure slightly more than 6 inches.
Project Lead The Way, Inc.
Copyright 2007

46. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Note: Some dial calipers have blade scales that are located above or below the rack
The blade scale shows each inch divided into 10 increments. Each increment equals one hundred thousandths (0.100”).
Project Lead The Way, Inc.
Copyright 2007

47. Slider Blade Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Slider
Blade
The blade is the immovable portion of the dial caliper.
The slider moves along the blade and is used to adjust the distance between the measuring surfaces.
Project Lead The Way, Inc.
Copyright 2007

48. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Pointer
The pointer rotates within the dial as the slider moves back-and-forth along the blade.
Project Lead The Way, Inc.
Copyright 2007

49. Reference Edge Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Reference Edge
The reference edge keeps track of the larger increments (i.e ”) as the slider moves along the rack.
Project Lead The Way, Inc.
Copyright 2007

50. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Rack
The gear-toothed rack is used to change linear motion (slider) to rotary motion (pointer).
Project Lead The Way, Inc.
Copyright 2007

51. Dial Calipers Reading the inch dial caliper Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Reading the inch dial caliper
Project Lead The Way, Inc.
Copyright 2007

52. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Note: Dial face divisions and increments are not standardized.
The dial is divided 100 times, with each graduation equaling one thousandth of an inch (0.001”).
Project Lead The Way, Inc.
Copyright 2007

53. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
Every time the pointer completes one rotation, the reference edge on the slider will have moved the distance of one blade scale increment (0.100”).
Project Lead The Way, Inc.
Copyright 2007

54. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
To determine the outside diameter of this pipe section, the user must first identify how many inches are being shown on the blade scale.
Project Lead The Way, Inc.
Copyright 2007

55. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
1.000”
The reference edge is located between the 1 and 2 inch marks. So, the user makes a mental note…1 inch.
0.400”
The user then identifies how many 0.1” increment marks are showing to the right of the last inch mark.
In this case, there are 4…or 0.400”.
Project Lead The Way, Inc.
Copyright 2007

56. Dial Calipers
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
1.000”
0.400” +
0.037”
1.437”
Next, the user looks at the pointer on the dial to see how many thousandths it is pointing to.
In this case, it is pointing to 37…or 0.037”.
The user then adds the three values together…
Project Lead The Way, Inc.
Copyright 2007

57. 1.000” 0.400” 0.002” + 1.402” Dial Calipers How wide is the block?
Introduction to Engineering DesignTM
Unit 1 – Lesson 1.3 – Measurement and Statistics
Dial Calipers
1.000”
0.400”
0.002” +
1.402”
How wide is the block?
Project Lead The Way, Inc.
Copyright 2007