MY-405: Industrial Quality Control in Metal Industries ...
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MY-405: Industrial Quality Control in Metal Industries Department of Metallurgical Engineering Page 1 Practical Workbook MY-405: Industrial Quality Control in Metal Industries Department of Metallurgical Engineering NED University of Engineering and Technology, Name ______________________ Roll No_____________________ Batch_______________________ Year_______________________
Transcript of MY-405: Industrial Quality Control in Metal Industries ...
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 1
Practical Workbook
MY-405 Industrial Quality Control in Metal Industries
Department of Metallurgical Engineering
NED University of Engineering and Technology
Karachi-75270 Pakistan
Name ______________________
Roll No_____________________
Batch_______________________
Year_______________________
Department_________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 2
Practical Workbook
MY-405 Industrial Quality Control in Metal Industries
This is to certify that this practical book contains 35 pages
Prepared by __________________
Junaid Nasir
Approved by __________________
Chairman MYD
Department of Metallurgical Engineering
NED University of Engineering and Technology
Karachi-75270 Pakistan
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 3
CERTIFICATE
It is certified that Mr Ms ___________________________________________ Student of
class ______________________________ Batch_________________ Bearing Roll No
_______________________________________ has completed hisher course work in the
subject of ____________________________________ as prescribed and approved by
Department of Metallurgical Engineering
Hisher performance is reflected by indexcontents of hisher practical workbook
Overall performance of the student is
Excellent
Very Good
Good
Satisfactory
Not Satisfactory
_____________
Course Teacher
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 4
TABLE OF CONTENTS
Practical No
Objective PAGE No Date INITIAL
1 Introduction of measuringinspection instruments and their specific use
1-5
2 Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
6-7
3 Calibrate a micrometer with slip gauges
8-9
4 Check concentricityeccentricity of a cam shaft on a run out testing equipment
10-12
5 Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using profile projector
13-14
6 Prepare a check sheet by measuring outer dia of Collar Oil Lock of CD 70 motor cycle
15-17
7 Prepare a histogram by measuring head dia of screw
18-20
8 Prepare Pareto diagram of defects found in Fastener
21-23
9 Find out the process capability of steel bar having 525 mm dia
24-26
10 Prepare a control chart by measuring thickness of Collar Oil Lock of CG 125 motor cycle
27-29
11 Use bore gauge to find ovality and taper in an Engine Sleeve
30-32
12 Accept or reject a lot based on single sampling using MIL-STD 105E
33-35
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 5
MY-405 Industrial Quality Control in Metal Industries
Precautions in Lab
1 Wash your hands before entering in the lab and make sure that your work area is clean
2 Never attempt to operate any equipment without prior permission of the instructor
3 Do not put anything in your mouth while in the lab Never eat chewing gum drink taste
chemicals smoke in the lab Do not bring food and drink into the laboratory
4 Do not place personal items (purses books bags coats umbrellas) on the lab table or at
your feet
5 Use inspection instruments with care and hold it firmly if it is in your hand
6 Avoid dropping of instruments and inspection pieces from your hand
7 Clean the slip gauges with cotton cloth apply grease after completing the practical and put
it back to its place in the box
8 Wash your hand with soup after completing the experiment
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 6
Practical No 1
Date ___________
Time ___________ Object Introduction of measuringinspection instruments and their specific use Instruments
Verniers Micrometers Depth gauges Height Gauges Dial indicators Inside micrometers (Hole testers) Profile Projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
Vernier
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
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Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
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Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
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Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
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Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
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EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
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Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 2
Practical Workbook
MY-405 Industrial Quality Control in Metal Industries
This is to certify that this practical book contains 35 pages
Prepared by __________________
Junaid Nasir
Approved by __________________
Chairman MYD
Department of Metallurgical Engineering
NED University of Engineering and Technology
Karachi-75270 Pakistan
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 3
CERTIFICATE
It is certified that Mr Ms ___________________________________________ Student of
class ______________________________ Batch_________________ Bearing Roll No
_______________________________________ has completed hisher course work in the
subject of ____________________________________ as prescribed and approved by
Department of Metallurgical Engineering
Hisher performance is reflected by indexcontents of hisher practical workbook
Overall performance of the student is
Excellent
Very Good
Good
Satisfactory
Not Satisfactory
_____________
Course Teacher
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 4
TABLE OF CONTENTS
Practical No
Objective PAGE No Date INITIAL
1 Introduction of measuringinspection instruments and their specific use
1-5
2 Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
6-7
3 Calibrate a micrometer with slip gauges
8-9
4 Check concentricityeccentricity of a cam shaft on a run out testing equipment
10-12
5 Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using profile projector
13-14
6 Prepare a check sheet by measuring outer dia of Collar Oil Lock of CD 70 motor cycle
15-17
7 Prepare a histogram by measuring head dia of screw
18-20
8 Prepare Pareto diagram of defects found in Fastener
21-23
9 Find out the process capability of steel bar having 525 mm dia
24-26
10 Prepare a control chart by measuring thickness of Collar Oil Lock of CG 125 motor cycle
27-29
11 Use bore gauge to find ovality and taper in an Engine Sleeve
30-32
12 Accept or reject a lot based on single sampling using MIL-STD 105E
33-35
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 5
MY-405 Industrial Quality Control in Metal Industries
Precautions in Lab
1 Wash your hands before entering in the lab and make sure that your work area is clean
2 Never attempt to operate any equipment without prior permission of the instructor
3 Do not put anything in your mouth while in the lab Never eat chewing gum drink taste
chemicals smoke in the lab Do not bring food and drink into the laboratory
4 Do not place personal items (purses books bags coats umbrellas) on the lab table or at
your feet
5 Use inspection instruments with care and hold it firmly if it is in your hand
6 Avoid dropping of instruments and inspection pieces from your hand
7 Clean the slip gauges with cotton cloth apply grease after completing the practical and put
it back to its place in the box
8 Wash your hand with soup after completing the experiment
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 6
Practical No 1
Date ___________
Time ___________ Object Introduction of measuringinspection instruments and their specific use Instruments
Verniers Micrometers Depth gauges Height Gauges Dial indicators Inside micrometers (Hole testers) Profile Projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
Vernier
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 3
CERTIFICATE
It is certified that Mr Ms ___________________________________________ Student of
class ______________________________ Batch_________________ Bearing Roll No
_______________________________________ has completed hisher course work in the
subject of ____________________________________ as prescribed and approved by
Department of Metallurgical Engineering
Hisher performance is reflected by indexcontents of hisher practical workbook
Overall performance of the student is
Excellent
Very Good
Good
Satisfactory
Not Satisfactory
_____________
Course Teacher
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 4
TABLE OF CONTENTS
Practical No
Objective PAGE No Date INITIAL
1 Introduction of measuringinspection instruments and their specific use
1-5
2 Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
6-7
3 Calibrate a micrometer with slip gauges
8-9
4 Check concentricityeccentricity of a cam shaft on a run out testing equipment
10-12
5 Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using profile projector
13-14
6 Prepare a check sheet by measuring outer dia of Collar Oil Lock of CD 70 motor cycle
15-17
7 Prepare a histogram by measuring head dia of screw
18-20
8 Prepare Pareto diagram of defects found in Fastener
21-23
9 Find out the process capability of steel bar having 525 mm dia
24-26
10 Prepare a control chart by measuring thickness of Collar Oil Lock of CG 125 motor cycle
27-29
11 Use bore gauge to find ovality and taper in an Engine Sleeve
30-32
12 Accept or reject a lot based on single sampling using MIL-STD 105E
33-35
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 5
MY-405 Industrial Quality Control in Metal Industries
Precautions in Lab
1 Wash your hands before entering in the lab and make sure that your work area is clean
2 Never attempt to operate any equipment without prior permission of the instructor
3 Do not put anything in your mouth while in the lab Never eat chewing gum drink taste
chemicals smoke in the lab Do not bring food and drink into the laboratory
4 Do not place personal items (purses books bags coats umbrellas) on the lab table or at
your feet
5 Use inspection instruments with care and hold it firmly if it is in your hand
6 Avoid dropping of instruments and inspection pieces from your hand
7 Clean the slip gauges with cotton cloth apply grease after completing the practical and put
it back to its place in the box
8 Wash your hand with soup after completing the experiment
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 6
Practical No 1
Date ___________
Time ___________ Object Introduction of measuringinspection instruments and their specific use Instruments
Verniers Micrometers Depth gauges Height Gauges Dial indicators Inside micrometers (Hole testers) Profile Projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
Vernier
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 4
TABLE OF CONTENTS
Practical No
Objective PAGE No Date INITIAL
1 Introduction of measuringinspection instruments and their specific use
1-5
2 Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
6-7
3 Calibrate a micrometer with slip gauges
8-9
4 Check concentricityeccentricity of a cam shaft on a run out testing equipment
10-12
5 Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using profile projector
13-14
6 Prepare a check sheet by measuring outer dia of Collar Oil Lock of CD 70 motor cycle
15-17
7 Prepare a histogram by measuring head dia of screw
18-20
8 Prepare Pareto diagram of defects found in Fastener
21-23
9 Find out the process capability of steel bar having 525 mm dia
24-26
10 Prepare a control chart by measuring thickness of Collar Oil Lock of CG 125 motor cycle
27-29
11 Use bore gauge to find ovality and taper in an Engine Sleeve
30-32
12 Accept or reject a lot based on single sampling using MIL-STD 105E
33-35
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 5
MY-405 Industrial Quality Control in Metal Industries
Precautions in Lab
1 Wash your hands before entering in the lab and make sure that your work area is clean
2 Never attempt to operate any equipment without prior permission of the instructor
3 Do not put anything in your mouth while in the lab Never eat chewing gum drink taste
chemicals smoke in the lab Do not bring food and drink into the laboratory
4 Do not place personal items (purses books bags coats umbrellas) on the lab table or at
your feet
5 Use inspection instruments with care and hold it firmly if it is in your hand
6 Avoid dropping of instruments and inspection pieces from your hand
7 Clean the slip gauges with cotton cloth apply grease after completing the practical and put
it back to its place in the box
8 Wash your hand with soup after completing the experiment
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 6
Practical No 1
Date ___________
Time ___________ Object Introduction of measuringinspection instruments and their specific use Instruments
Verniers Micrometers Depth gauges Height Gauges Dial indicators Inside micrometers (Hole testers) Profile Projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
Vernier
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 5
MY-405 Industrial Quality Control in Metal Industries
Precautions in Lab
1 Wash your hands before entering in the lab and make sure that your work area is clean
2 Never attempt to operate any equipment without prior permission of the instructor
3 Do not put anything in your mouth while in the lab Never eat chewing gum drink taste
chemicals smoke in the lab Do not bring food and drink into the laboratory
4 Do not place personal items (purses books bags coats umbrellas) on the lab table or at
your feet
5 Use inspection instruments with care and hold it firmly if it is in your hand
6 Avoid dropping of instruments and inspection pieces from your hand
7 Clean the slip gauges with cotton cloth apply grease after completing the practical and put
it back to its place in the box
8 Wash your hand with soup after completing the experiment
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 6
Practical No 1
Date ___________
Time ___________ Object Introduction of measuringinspection instruments and their specific use Instruments
Verniers Micrometers Depth gauges Height Gauges Dial indicators Inside micrometers (Hole testers) Profile Projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
Vernier
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 6
Practical No 1
Date ___________
Time ___________ Object Introduction of measuringinspection instruments and their specific use Instruments
Verniers Micrometers Depth gauges Height Gauges Dial indicators Inside micrometers (Hole testers) Profile Projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
Vernier
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 7
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Micrometer
Depth Gauge
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 8
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Height Gauge
Hole Tester
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 9
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Profile Projector
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 10
EXERCISE 1 Q 1 What is Coordinate Measuring Machine (CMM) ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Name three instruments (machines) for gear teeth checking ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 11
Practical No 2 Date ___________
Time ___________
Object Use slip gauges to build dimensions 28955 mm 37605 mm 44540 mm and 57 215 mm dimensions
Instrument Slip gauge 47 pieces set
Procedure
Take out required slip gauges from the box Clean the slip gauges with a soft cotton cloth Wring the slip gauges by sliding the polished surfaces to each other After wringing of all slip gauges check the dimension from micrometer Separate the slip gauges by sliding to each other Apply light grease or oil on the slip gauges and put back to their places in
the box Observations
1 28955 mm = 2 37605 mm = 3 44540 mm =
4 57 215 mm =
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 12
EXERCISE 2
Q 1 Name various grades of slip gauges ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Where are slip gauges used ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 13
Practical No 3
Date ___________
Time ___________ Object Calibrate a micrometer with slip gauges
Instruments Slip gauge 47 pieces set
Micrometer 0-25 mm
Procedure
Clean the micrometer with soft cotton cloth Touch the spindle with the anvil of micrometer by moving the ratchet Set the reading zero by pressing the button on micrometer Take slip gauges of 5101520 and 25 mm Check the dimensions of slip gauges from micrometer and note the
deviation if any Observations
S No Slip Gauge Dimension Micrometer Reading 1 5 mm 2 10 mm 3 15 mm 4 20 mm 5 25 mm
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 14
EXERCISE 3
Q 1 What is calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Discuss the clause of ISO 9001 standard which describes the requirement of calibration
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 15
Practical No 4
Date ___________
Time ___________ Object Check concentricityeccentricity of a cam shaft on a run out testing equipment
Instruments Run out testing equipment Dial indicator Magnetic Stand Surface plate
Part to be measured Cam Shaft Procedure
Put the cam shaft between the centres of run out testing equipment
Place it on a surface table
Put a dial indicator on a magnetic stand and place it on surface table near the cam shaft
Rotate the cam shaft between centres to find its minimum dia
Put the stem of dial indicator on the cam shaft minimum dia and make it zero
Now rotote the cam shaft and note the reading of dial indicator at maximum dia
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 16
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 17
EXERCISE 4 Q 1 Give some applications of cam shaft ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Differentiate among concentricity roundness and cylindricity of a part How they are shown on an engineering drawing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 18
Practical No 5 Date ___________
Time ___________
Object Find out groove width and groove angle of Guide Rod of Yamaha motor cycle using
profile projector
Instrument
Profile projector
Procedure
Put the part on the table of profile projector
Set the required magnification
Switch on the light and focus the part
Trace the part on a butter paper and check the required dimensions or check the dimensions on the profile projector screen by DRO or templates
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 19
EXERCISE 5
Q 1 What is a profile projector
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Name some optical measuring instruments
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 20
Practical No 6 Date ___________
Time ___________
Object Prepare a check sheet by measuring outer dia of Collar Oil lock of CD 70 motor cycle
Instrument Micrometer 0-25 mm
Part to be measured Collar Oil Lock of CD 70 Motor Cycle
Procedure Measure OD of collar oil lock and note it on a table
Prepare check sheet
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 21
Check Sheet
Class Intervals Tally Frequency
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 22
EXERCISE 6 Q 1 What is a check sheet ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Q2 Describe a few types of check sheet formats ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 23
Practical No 7 Date ___________
Time ___________
Object Prepare a histogram by measuring head dia of screw
Instrument Digital vernier
Part to be measured frac34 x8 screw Procedure
Measure the head dia of screws and note it in table
Prepare Histogram by making class intervals
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 24
Frequency table
Class intervals Tally Frequency
Histogram
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 25
EXERCISE 7 Q 1 Name different pattern of Histograms
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Q2 What information a histogram gives about mean and standard deviation of a process if specification limits are drawn on it
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 26
Practical No 8 Date ___________
Time ___________
Object Prepare Pareto diagram of defects found in Fastener
Procedure Separate fasteners of different defects
Count fasteners found in each defect
Prepare a frequency table and then plot a Pareto graph
Observations
S No Defects Numbers Percentage
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 27
Pareto Graph
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 28
EXERCISE 8
Q 1 What techniques are used to solve the vital problem found in a Pareto graph
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 How can you prepare a Pareto graph by using MS EXCEL
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 29
Practical No 9
Date ___________
Time ___________ Object Find out the process capability of steel bar having 525 mm dia
Instrument Micrometer 0-25 mm
Part to be measured Steel bar pieces (30)
Procedure
Measure the diameters of steel bar pieces and note it in a table
Calculate the mean and standard deviation of the sample
Apply process capability formula to find process capabilities
Observations
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 30
Calculations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 31
EXERCISE 9
Q 1 Would you accept a lot if all parts found in the sample drawn from the lot are with in the specification limits Explain
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is Taguchi capability index
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 32
______________________________________________________________________________
Practical No 10
Date ___________
Time ___________ Object Prepare a control chart by measuring thickness of collar oil lock of CG 125 motor cycle
Instrument Vernier
Part to be measured Collar Oil lock of CG 125 motor Cycle Procedure
Take 5 samples after every hour from a press
Measure the thickness of the samples and record it on the control chart sheet
Calculate mean range and control limits
Draw the graph X -R chart
Observations
Time
1
2
3
4
5
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 33
Calculations
Control Chart
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 34
EXERCISE 10
Q 1 Discuss different patterns of control charts
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What is the difference between control limits and specification limits
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 35
Practical No 11
Date ___________
Time ___________ Object Use bore gauge to find ovality and taper in an engine sleeve
Instrument
Bore Gauge Part to be measured Engine Sleeve
Procedure
Clean the sleeve
Set the bore gauge close to ID of sleeve
Put the bore gauge into the sleeve and move the spring loaded pin up and down
Take the minimum reading of the dial
Now take the reading by moving the bore gauge to 180o
Move the bore gauge along the length of the sleeve and take readings in the same way as described above
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 36
Observations
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 37
EXERCISE 11
Q 1 How can ovality and taper be removed from an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 What are the materials of an engine sleeve
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 38
Practical No 12
Date ___________
Time ___________ Object Accept or reject a lot based on single sampling using MIL-STD 105E
Instrument
Plug gauge
Part to be checked
Washing machine bush
Lot Size 500
Inspection Level General II
AQL 065
Procedure
Check ID of bush from plug gauge Separate bushes in which Go side of gauge is not going or Not go side is going from OK
bushes and count them
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 39
Observations
Samples size
No of defective parts found
Results
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
MY-405 Industrial Quality Control in Metal Industries Department of Metallurgical Engineering
Page 40
EXERCISE 12
Q 1 What is MIL STD 105
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
Q2 Explain different types of sampling plan
______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________
