Introduction to Quality Engineering

Discover the pathway to quality engineering by studying 12 core areas: measurement, calibration, data and risk analysis, quality planning and system development, auditing, root cause analysis, training, and leadership.

Overview of quality engineering covers metrology, part and process measurement, calibration, and measurement error. Explore failure modes and effects analysis, audits, eight-step problem solving, Six Sigma, lean, training, leadership.

Measure parts to verify they meet engineering requirements using gauges and hand tools. Learn to select appropriate gauges, compare manufacturing outcomes to drawings, and practice calipers and micrometers.

Explore common handheld measurement tools on factory floors, including calipers, depth gauges, micrometers, and indicators, with notes on digital and analog variants.

Master digital thickness gauges, go/no-go attribute gauges, and radius gauges to quickly verify sheet metal parts and tolerances in production.

Learn how vernier calipers and the vernier scale measure in centimeters by aligning lines on the main and vernier scales to obtain readings such as 1.165 cm for quality engineering.

Explore digital indicator gauge applications, using masters to zero and measure part differences, including outside diameters, snap gauges, gauge stands, gauge plates, and gauge blocks.

Explore automated part measurement in high-volume manufacturing by using vibratory bowls, conveyors, and sensors to weigh, gauge dimensions, compare to tolerances, and sort parts into good and reject bins.

Explore how quality engineers design process measurement to monitor parameters like pressure, temperature, flow, viscosity, revolutions per minute, and chemical properties with digital and analog gauges, for continuous monitoring.

Explore real-time digital process measurement in a parts washer with three temperature controllers for wash, rinse, and blow-off, featuring set points, actual temperatures, and data exports for alarms and Andon.

Calibration compares a measurement device against a traceable reference to quantify accuracy and gauge error; gauge blocks serve as the reference standard to verify and calibrate tools.

Gauge blocks, with calibration certificates, verify and calibrate gauges in a lab by ringing blocks like 25 and 1 to form 26 millimeters and checking with calipers.

Compare short form and long form calibration certificates, including certificate of conformance and traceability, ISO, and NIST, and understand shift and load tests with as found and as left readings.

Quality engineers oversee calibration programs for shopfloor tools, establishing procedures and limits, and comparing gauge blocks and calipers to reference standards to accept, reject, or adjust outputs.

Assess measurement error within the measurement system, focusing on repeatability and reproducibility, and apply a ten by three by three gauge R&R study.

Explore the GR&R form with ten by three by three design in Excel to assess gauge and part variation across operators, and learn control limits and percent of total tolerance.

Learn to analyze and visualize process data to gain insights and draw conclusions. Explore the seven basic quality tools and Excel applications for quality engineering.

Explore the seven quality tools, including histograms, parade diagrams, and flow charts, to support define, measure, analyze, improve, and control in Lean Six Sigma quality engineering.

Explore the seven quality tools, from the checklist to run charts and control charts, and end with scatterplots, correlation, and regression for process capability.

Analyze data in Excel with mean, max, min, and range, and visualize distributions using histograms to compare processes for quality engineering.

Explore failure modes and effects analysis (FMEA) as a core risk analysis tool in quality engineering, covering design FMA and process FMA, severity, occurrence, detection, and the risk priority number.

Explore how FMEA is implemented in Excel to analyze sensor mounting seal failures in a refrigeration unit, detailing severity, occurrence, detection, and RPM to drive design improvements.

This lecture explains quality planning and the process control plan as the blueprint for delivering a part that meets customer expectations on time and at cost, detailing measurement and responsibilities.

Explore how a quality management system documents processes and responsibilities to achieve quality policies, guided by ISO 9001, from upstream engineering and supplier selection to downstream service and warranty.

Learn how to build a process control plan in Excel, including header data, process steps, key product and control characteristics, tolerances, measurement methods, sampling, responsibilities, and a reaction plan.

Compare ISO 9001 and AS 9100, highlighting their common foundations and structures, and explain how to identify, control, and verify nonconforming outputs to ensure conformity.

Explore quality auditing as a systematic, independent, documented review of a quality management system to verify compliance with objectives and uncover improvement opportunities across product, process, and system.

Learn acceptance sampling, a quality control method rooted in inferential statistics that uses aql tables and sampling plans (like level two, j) to assess a batch’s quality without 100% inspection.

Lead root cause analysis and process improvement to reduce defects. Differentiate corrective actions from preventive actions and apply observation and data analysis to drive lead time improvements.

Explore four major problem solving frameworks for quality engineering, including dmaic, eight d, lean manufacturing, and six sigma, with tools for measure, analyze, improve, and control.

Explore lean manufacturing and the seven wastes: waiting, overproduction, over processing, defects, motion, inventory, and transportation, and how non-value-added activities reduce return on investment and value-added work.

Explore the six M's of Six Sigma—machine, method, man, material, measurement, and Mother Nature—as a framework to brainstorm sources of variation and prevent defects.

Lead training as a quality engineering task, aligning safety, quality systems, and cross-functional needs. Continuously learn and mentor others, using formal or informal networks and resources like Udemy and ASQ.

Align your efforts with the organization's top objectives to move from individual contributor to leader through collaboration, team building, and project management.

Develop leadership skills beyond technical expertise by building teams, listening, delegating, solving problems, and mastering soft skills and finance concepts ROI and IRR to advance from individual contributor to leader.

Conclude the course by reinforcing lifelong learning for quality engineers and the evolving skills, strategies, and methods essential to quality systems, with lifetime access to all course materials.

Ray Harkins promotes continuous learning for quality professionals and points to five Udemy courses, including root cause analysis, DX corrective action, statistical process control, Lean Six Sigma, and reliability engineering.