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The Handbook for Quality Technicians and Mechanical
Inspectors
 by
Thomas Pyzdek
Table of Contents:
I Quality control concepts and techniques
1
A Total quality control concepts 1
1 New design control 1
2 Purchased material control 5
3 Product and process control 12
4 Special processes control 18
5 Work elements of quality systems
19
B Classification of characteristics and
nonconformances 26
C Determination of inspection points
and methods 28
1 Purchased material 33
2 Work in process 33
3 Final inspection and test 39
4 Shipping inspection 41
5 Documentation methods 42
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D Inspection methods 43
1 100% inspection 43
2 Different types and methods of sampling
48
3 Nondestructive testing and examination
49
4 Destructive testing 51
E Nonconforming material control 51
1 Identification and segregation 51
2 Materials review principles 62
3 Dispositions 63
4 Corrective action and recurrence
control 63
F Quality data 64
G Quality Tools 70
1 PDCA (Plan-Do-Check-Act) 70
2 Principles of team leadership and
facilitation 75
3 Team dynamics management, including
conflict resolution 77
H Basic probability concepts 84
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II Fundamentals of practical statistical
methods 91
A Presentation, description, and analysis
of data 91
1 Frequency distribution of data: normal,
bimodal, skewed 91
2 Measurement of central tendency 103
3 Measurement of variation 104
4 Measurement of correlation 105
B Sampling distributions 114
1 Mean 114
2 Variance 114
3 Proportion 115
4 Range 115
5 Normal 116
6 Poisson 120
7 Binomial 121
8 Pareto 122
C Statistical inference 125
D Control charts 139
1 General concepts 139
2 State of statistical control 144
3 Control limits 146
4 Pre-control 149
5 Process capability 153
6 Rational subgroupings 165
7 Variables charting 166
8 Attribute charting 181
9 Machine capability 197
10 Analysis of charts 200
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III Application of sampling principles
217
IV Reliability principles, applications,
and simple calculations 237
V Metrology and calibration fundamentals
257
A Common international standards of measurement
263
B Measurement standards and traceability
265
VI Quality data, analysis, problem solving,
and cost methodology 325
VII Quality audit concepts and principles
349
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VIII Technical Mathematics 369
A Shop math 369
1 Fractions 369
2 Decimals 373
3 Squares 378
4 Square roots 378
B Algebra 379
1 Use of letters and signed numbers
379
2 Fundamental operations in algebra
386
C Plane geometry 396
D Trigonometry 429
1 Angles and measurements 430
2 The trigonometric functions 443
3 Problems involving right triangles
460
4 Problems involving oblique triangles
468
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Appendix 499
Table 1 Quality Auditing terminology
501
Table 2 Audit standards and standards
organizations 514
Table 3 Glossary of basic statistical
terms 516
Table 4 Area under the standard normal
curve 524
Table 5 Critical values of the t-distribution
527
Table 6 Chi-square distribution 529
Table 7 F distribution (a=1%) 532
Table 8 F distribution (a=5%) 534
Table 9 Poisson probability sums 536
Table 10 y factors for computing AOQL
540
Table 11 Control chart constants 541
Table 12 Control chart equations 543
Table 13 Mil-Std-45662 Military standard:
calibration system requirements 545
Table 14 Table of d2* values 555
Table 15 Equivalent measurements of angles
557
Table 16 Right angles expressed in degrees
and radians 558
Table 17 Degrees and minutes expressed
in radians 559
Table 18 Signs of the trigonometric functions
560
Table 19 Values of the trigonometric
functions, q as multiple of 90° 561
Table 20 Values of the trigonometric
functions, q ± multiples of 90° in terms of q 562
Table 21 Values of the trigonometric
functions, q at selected intervals 563
Table 22 Greek alphabet 564
Table 23 Values of the trigonometric
functions, sin, cos, tan, cot 565
Table 24 Logarithms of trigonometric
functions 572
Table 25 Mathematical notation 579
Table 26 Metric interrelationships 580
Table 27 Conversions, weights, and measures:
equivalents 582
References 587
Index 593
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