The Certified Quality Inspector Handbook

481 Pages·2012·6.54 MB·English

by  H. Fred Walker

The Certified Quality
Inspector Handbook
H1427_Walker_full_book.indd 1 8/29/12 11:57 AM
Also available from ASQ Quality Press:
The Certified Quality Technician Handbook, Second Edition
H. Fred Walker, Donald W. Benbow, and Ahmad K. Elshennawy
The Certified Quality Engineer Handbook, Third Edition
Connie M. Borror, editor
The Metrology Handbook, Second Edition
Jay L. Bucher, editor
The Uncertainty of Measurements: Physical and Chemical Metrology Impact and Analysis
S. K. Kimothi
Quality Audits for Improved Performance, Third Edition
Dennis R. Arter
Reliability Data Analysis with Excel and Minitab
Kenneth S. Stephens
HALT, HASS, and HASA Explained: Accelerated Reliability Techniques, Revised Edition
Harry W. McLean
The Quality Toolbox, Second Edition
Nancy R. Tague
Root Cause Analysis: Simplified Tools and Techniques, Second Edition
Bjørn Andersen and Tom Fagerhaug
The Certified Manager of Quality/Organizational Excellence Handbook: Third Edition
Russell T. Westcott, editor
To request a complimentary catalog of ASQ Quality Press publications, call
800-248-1946, or visit our website at http://www.asq.org/quality-press.
H1427_Walker_full_book.indd 2 8/29/12 11:57 AM
The Certified Quality
Inspector Handbook
Second Edition
H. Fred Walker, Ahmad Elshennawy,
Bhisham C. Gupta, and Mary McShane Vaughn
ASQ Quality Press
Milwaukee, Wisconsin
H1427_Walker_full_book.indd 3 8/29/12 11:57 AM
American Society for Quality, Quality Press, Milwaukee 53203
© 2013 by ASQ
All rights reserved. Published 2012
Printed in the United States of America
17 16 15 14 13 12 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data to come
The certified quality inspector handbook / H. Fred Walker . . . [et al.].—2nd ed.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-87389-845-4 (alk. paper)
1. Quality control—Handbooks, manuals, etc. 2. Quality control inspectors—
Certification—United States. I. Walker, H. Fred, 1963–
TS156.C42345 2012
658.5′62—dc23
2012027602
No part of this book may be reproduced in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the publisher.
Publisher: William A. Tony
Acquisitions Editor: Matt Meinholz
Project Editor: Paul Daniel O’Mara
Production Administrator: Randall Benson
ASQ Mission: The American Society for Quality advances individual, organizational, and
community excellence worldwide through learning, quality improvement, and knowledge
exchange.
Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, video,
audio, and software are available at quantity discounts with bulk purchases for business,
educational, or instructional use. For information, please contact ASQ Quality Press at
800-248-1946, or write to ASQ Quality Press, P.O. Box 3005, Milwaukee, WI 53201-3005.
To place orders or to request a free copy of the ASQ Quality Press Publications Catalog, visit our
website at http://www.asq.org/quality-press.
Printed on acid-free paper
H1427_Walker_full_book.indd 4 8/29/12 11:57 AM
In loving memory of my father, Carl Ellsworth Walker.
—Fred
In loving memory of my mother, Ikram.
—Ahmad
In loving memory of my parents, Roshan Lal and Sodhan Devi.
—Bhisham
In loving memory of my father, Charles H. McShane.
—Mary
H1427_Walker_full_book.indd 5 8/29/12 11:57 AM
H1427_Walker_full_book.indd 6 8/29/12 11:57 AM
Table of Contents
List of Figures and Tables ................................................. xiii
Preface ................................................................ xxi
Acknowledgments ....................................................... xxii
How to Use This Book .................................................... xxiii
Section I Technical Mathematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1 A . Basic Shop Math . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Properties of Real Numbers .......................................... 2
Positive and Negative Numbers ...................................... 2
Fractions .......................................................... 3
Decimals .......................................................... 7
Squares and Square Roots ........................................... 9
Order of Operations ................................................ 10
Factorials .......................................................... 10
Truncating, Rounding, and Significant Digits ........................... 10
Chapter 2 B . Basic Algebra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Solving Algebraic Equations ......................................... 12
Chapter 3 C . Basic Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Areas of Basic Geometric Shapes ..................................... 18
Perimeter and Circumference of Basic Geometric Shapes ................. 20
Volume of Basic Geometric Shapes .................................... 22
Surface Area of Basic Geometric Shapes ............................... 23
Complementary and Supplementary Angles ........................... 25
Chapter 4 D . Basic Trigonometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
The Right Triangle .................................................. 26
Trigonometric Functions ............................................. 27
Solving for Unknown Sides and Angles of a Right Triangle ............... 29
Inverse Trigonometric Functions ...................................... 31
Oblique Triangles ................................................... 31
Solving Oblique Triangles ........................................... 31
Chapter 5 E . Measurement Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Measurement Systems .............................................. 37
English System Measurements ....................................... 37
vii
H1427_Walker_full_book.indd 7 8/29/12 11:57 AM
viii Table of Contents
SI/Metric System Measurements ..................................... 41
English-to-SI/Metric Conversions .................................... 44
Chapter 6 F . Numeric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Exponents ......................................................... 49
Scientific Notation .................................................. 50
Decimals and Fractions .............................................. 52
Section II Metrology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 7 A . Common Gauges and Measurement Instruments . . . . . . . . . . . . 56
Introduction ....................................................... 56
1. Variable Gauges .................................................. 57
2. Attribute Gauges ................................................. 63
3. Transfer Gauges .................................................. 69
4. Measurement Scales .............................................. 69
Chapter 8 B . Special Gauges and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1. Electronic Gauging Tools .......................................... 71
2. Automatic Gauging Components ................................... 73
3. Pneumatic Gauging Components ................................... 77
Summary of Gauge Uses and Applications ............................. 79
Chapter 9 C . Gauge Selection, Handling, and Use . . . . . . . . . . . . . . . . . . . . . . . 83
1. Gauge Selection .................................................. 83
2. Gauge Handling, Preservation, and Storage .......................... 84
3. Gauge Correlation ................................................ 86
Chapter 10 D . Surface Plate Tools and Techniques . . . . . . . . . . . . . . . . . . . . . . . 88
1. Surface Plate Equipment .......................................... 88
2. Angle Measurement Instruments ................................... 90
Chapter 11 E . Specialized Inspection Equipment . . . . . . . . . . . . . . . . . . . . . . . . 94
1. Measuring Mass .................................................. 94
2. Measuring Finish ................................................. 98
3. Measuring Shape and Profile ....................................... 100
4. Optical Equipment ............................................... 100
5. Digital Vision Systems ............................................ 105
6. Coordinate Measuring Machine (CMM) ............................. 107
Chapter 12 F . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1. Calibration Systems ............................................... 112
2. Calibration Standards ............................................. 116
3. Equipment Traceability ............................................ 117
4. Gauge Calibration Environment .................................... 118
5. Out-of-Calibration Effects ......................................... 118
Chapter 13 G . Measurement System Analysis (MSA) . . . . . . . . . . . . . . . . . . . . 120
Process Variability .................................................. 121
Evaluating Measurement System Performance ......................... 121
The Range-Based Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
The ANOVA Method ................................................ 127
Measurement Capability Indices ...................................... 133
H1427_Walker_full_book.indd 8 8/29/12 11:57 AM
Table of Contents ix
Section III Inspection and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Chapter 14 A . Blueprints, Drawings, Geometric Dimensioning
& Tolerancing (GD&T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Introduction ....................................................... 136
1. Blueprints and Engineering Drawings ............................... 137
2. Terminology and Symbols ......................................... 142
3. Position and Bonus Tolerances ..................................... 145
4. Part Alignment & Datum Structure ................................. 147
Chapter 15 B . Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Introduction ....................................................... 149
Advantages ........................................................ 150
Sampling Concepts ................................................. 151
Types of Attribute Sampling Plans .................................... 153
Sampling Standards and Plans ....................................... 154
Variables Sampling Plans ............................................ 156
Sequential Sampling Plans ........................................... 157
Continuous Sampling Plans .......................................... 158
Chapter 16 C . Inspection Planning and Processes . . . . . . . . . . . . . . . . . . . . . . . . 161
Introduction ....................................................... 161
Inspection Planning ................................................. 162
1. Inspection Types ................................................. 163
2. Inspection Errors ................................................. 166
3. Product Traceability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4. Identification of Nonconforming Material ........................... 171
5. Level of Severity ................................................. 172
Control of Nonconforming Materials .................................. 173
6. Disposition of Nonconforming Material ............................. 176
Chapter 17 D . Testing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1. Nondestructive Testing ............................................ 179
2. Destructive Testing ............................................... 186
3. Functionality Testing .............................................. 189
4. Hardness Testing ................................................. 191
Chapter 18 E . Software for Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Software Testing .................................................... 196
Testing vs. Inspection ............................................... 197
Functional Testing in Software Development ........................... 197
Software Testing Terminology ........................................ 198
Section IV Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Chapter 19 A . Basic Statistics and Applications . . . . . . . . . . . . . . . . . . . . . . . . . 206
Graphical Displays ................................................. 206
Numerical Methods ................................................. 223
Normal Distribution ................................................ 241
Chapter 20 B . Statistical Process Control (SPC) . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Basic Concepts of Quality and Its Benefits ............................. 250
What Is a Process? .................................................. 251
H1427_Walker_full_book.indd 9 8/29/12 11:57 AM