
The Certified Quality Inspector Handbook
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Content
- Cover
- Title Page
- CIP Data
- Dedication
- Table of Contents
- List of Figures and Tables
- Preface
- Acknowledgments
- How to Use This Book
- Section I: Technical Mathematics
- Chapter 1: A. Basic Shop Math
- Properties of Real Numbers
- Positive and Negative Numbers
- Adding and Subtracting with Positive and Negative Numbers
- Multiplying and Dividing with Positive and Negative Numbers
- Fractions
- Equivalent Fractions
- Simplified Fractions
- Proper and Improper Fractions
- Adding and Subtracting Fractions with Like Denominators
- Adding and Subtracting Fractions with Unequal Denominators
- Adding or Subtracting Mixed Numbers
- Multiplying and Dividing Fractions
- Decimals
- Decimal and Fraction Equivalents
- Converting Fractions to Decimals
- Rational and Irrational Numbers
- Converting Decimals to Percentages
- Adding and Subtracting Decimals
- Multiplying and Dividing Decimals
- Squares and Square Roots
- Imaginary Numbers
- Exponents
- Order of Operations
- Factorials
- Truncating, Rounding, and Significant Digits
- Adding and Subtracting Measurements
- Multiplying and Dividing Using Significant Digits
- Bibliography
- Chapter 2: B. Basic Algebra
- Solving Algebraic Equations
- Properties of Real Numbers
- Inverse Operations
- Solving Equations Using One Inverse Operation
- Solving Equations Using Two or More Inverse Operations
- Solving Equations by Collecting Terms
- Solving Equations with Parentheses
- Solving Inequalities
- Solving Inequalities with Negatively Signed Values
- Bibliography
- Chapter 3: C. Basic Geometry
- Areas of Basic Geometric Shapes
- Examples of Area Calculations
- Perimeter and Circumference of Basic Geometric Shapes
- Examples of Perimeter and Circumference Calculations
- Volume of Basic Geometric Shapes
- Examples of Volume Calculations
- Surface Area of Basic Geometric Shapes
- Examples of Surface Area Calculations
- Complementary and Supplementary Angles
- Bibliography
- Chapter 4: D. Basic Trigonometry
- The Right Triangle
- Pythagorean Theorem
- Trigonometric Functions
- Values of Trigonometric Functions for Some Common Angles
- Trigonometric Identities
- Solving for Unknown Sides and Angles of a Right Triangle
- Finding the Unknown Angle
- Finding the Unknown Sides
- Inverse Trigonometric Functions
- Oblique Triangles
- Solving Oblique Triangles
- Law of Sines
- Law of Cosines
- Three Sides Known
- Two Sides and an Angle between Them Known
- One Side and Two Angles Known
- Bibliography
- Chapter 5: E. Measurement Systems
- Measurement Systems
- English System Measurements
- SI/Metric System Measurements
- English-to-SI/Metric Conversions
- Bibliography
- Chapter 6: F. Numeric Conversions
- Exponents
- Positive Exponents
- Negative Exponents
- Powers of 10
- Scientific Notation
- Procedure for Values Greater Than 1 or Less Than -1
- Procedure for Values between -1 and +1
- Converting Scientific Notation back to Original Form
- Decimals and Fractions
- Converting Fractions to Decimals
- Converting Decimals to Fractions
- Bibliography
- Section II: Metrology
- Chapter 7: A. Common Gauges and Measurement Instruments
- Introduction
- 1. Variable Gauges
- Steel Rules
- Verniers
- Micrometers
- Vernier Scales
- Digital Micrometers
- Micrometer Calipers
- Gauge Blocks
- Dial Indicators
- Borescopes
- Thermometers and Temperature Probes
- Coordinate Measuring Machines
- 2. Attribute Gauges
- Common Gauges
- 3. Transfer Gauges
- 4. Measurement Gauges
- Reference
- Bibliography
- Chapter 8: B. Special Gauges and Applications
- 1. Electronic Gauging Tools
- Advantages
- Oscilloscopes
- Multimeters
- Pyrometers
- 2. Automatic Gauging Components
- Interferometry
- Machine Vision
- X-Ray Inspection
- 3. Pneumatic Gauging Components
- 4. Force Gauging
- 5. Environmental Instrumentation
- Summary of Gauge Uses and Applications
- References
- Bibliography
- Chapter 9: C. Gauge Selection, Handling, and Use
- 1. The Rule of Ten (10:1 Rule)
- 2. Gauge Selection
- 3. Gauge Handling, Preservation, and Storage
- 4. Gauge Correlation
- Reference
- Bibliography
- Chapter 10: D. Surface Plate Tools and Techniques
- 1. Surface Plate Equipment
- Surface Plate
- Dial Indicators
- Vernier Height Gauge
- 2. Angle Measurement Instruments
- Sine Bar
- Angle Blocks
- Protractors
- Reference
- Bibliography
- Chapter 11: E. Specialized Inspection Equipment
- 1. Measuring Mass
- Weights, Balances, and Scales
- Measuring Weight and Mass
- Balances and Scales
- Surface Metrology
- 2. Measuring Finish
- 3. Measuring Shape and Profile
- Comparators
- Measurement of Roundness
- 4. Optical Equipment
- Optical Tooling
- 5. Software-Based Measurement Systems
- Machine Vision Systems
- Laser Trackers
- Other Digital Inspection Systems
- 6. Measuring Inclination
- References
- Bibliography
- Chapter 12: F. Calibration
- 1. Calibration Systems
- Calibration Interval Prompt
- Uncertainty
- Tracking and Identification Methods
- Calibration Documentation and History
- Calibration Equipment
- Calibration Procedures
- 2. Calibration Standards and Equipment Traceability
- Equipment Traceability
- 3. Gauge Calibration Environment
- 4. Out-of-Calibration Effects
- References
- Bibliography
- Chapter 13: G. Measurement System Analysis (MSA)
- 1. Process Variability
- Variability in the Measurement Process
- 2. Evaluating Measurement System Performance
- 3. The Range-Based Method
- 4. The ANOVA Method
- Gauge R&R Study-ANOVA Method
- Graphical Representation of Gauge R&R Study
- 5. Measurement Capability Indices
- MCI as a Percentage of Process Variation (MCIpv)
- MCI as a Percentage of Process Specification (MCIps)
- References
- Section III: Inspection and Test
- Chapter 14: A. Blueprints, Drawings, Geometric Dimensioning & Tolerancing (GD&T) and Model Based Definitions
- Introduction
- 1. Blueprints and Engineering Drawings, and Model Based Definitions
- Sections of Technical Drawings
- Model Based Definition
- 2. Terminology and Symbols
- 3. Position and Bonus Tolerances
- 4. Part Alignment and Datum Structure
- References
- Chapter 15: B. Sampling
- Introduction
- Advantages
- Sampling Concepts
- Random Sampling
- The Operating Characteristic Curve
- Acceptance Sampling by Attributes
- Acceptance Quality Limit
- Lot Tolerance Percent Defective
- Producer's and Consumer's Risks
- Average Outgoing Quality
- Average Outgoing Quality Limit
- Lot Size, Sample Size, and Acceptance Number
- Types of Attribute Sampling Plans
- Single Sampling Plans
- Double Sampling Plans
- Multiple Sampling Plans
- Sampling Standards and Plans
- ANSI/ASQ Z1.4-2008
- Levels of Inspection
- Types of Sampling
- Variables Sampling Plans
- ANSI/ASQ Z1.9-2008
- Sequential Sampling Plans
- Continuous Sampling Plans
- MIL-STD-1235B
- References
- Bibliography
- Chapter 16: C. Inspection Planning and Processes
- Introduction
- Inspection Planning
- 1. Inspection Types
- Incoming Material Inspection
- First-Piece Inspection
- In-Process Inspection
- Final Inspection
- 2. Inspection Errors
- Inspector Qualifications and Training
- The Characteristics of a Quality Inspector
- 3. Product Traceability
- Factors to Consider
- 4. Identification of Nonconforming Material
- Principles of Identification
- Mechanics
- 5. Levels of Severity
- Control of Nonconforming Materials
- Control of Nonconforming Product
- Corrective Action
- Preventive Action
- 6. Disposition of Nonconforming Material
- Material Segregation
- Material Review Board
- References
- Bibliography
- Chapter 17: D. Testing Methods
- 1. Nondestructive Testing
- Definition
- NDT Applications and Objectives
- Methods of NDT
- 2. Destructive Testing
- Definition
- Destructive Testing Applications and Objectives
- Methods of Destructive Testing
- 3. Functionality Testing
- Definition
- Functionality Testing Objectives
- Methods of Functionality Testing
- 4. Hardness Testing
- Brinell
- Rockwell
- Vickers
- Microhardness Test
- References
- Chapter 18: E. Software for Test Equipment
- Software Testing
- Testing versus Inspection
- Functional Testing in Software Development
- Software Testing Terminology
- Automated Software Testing
- Automated Testing Tools
- Basis Path Testing
- Basis Test Set
- Bebugging
- Benchmark Testing
- Benchmark Testing Methods
- Compatibility Testing
- Debugging
- Desk Checking
- Design-Based Testing
- Dynamic Testing
- Functional Decomposition
- Functional Requirements
- Manual Testing
- Metric
- Modified Condition/Decision Coverage
- Modified Condition/Decision Testing
- Monkey Testing
- Negative Testing
- Portability Testing
- Positive Testing
- Recovery Testing
- Security Testing
- Traceability
- Validation Testing
- References
- Bibliography
- Section IV: Quality Assurance
- Chapter 19: A. Basic Statistics and Applications
- 1. Graphical Methods
- Frequency Distribution Table
- Qualitative Data
- Quantitative Data
- Dot Plot
- Pie Chart
- Bar Chart
- Pareto Chart
- Scatter Plot
- Histograms
- Stem-and-Leaf Diagram
- 2. Numerical Methods
- Measures of Centrality
- Measures of Dispersion
- Measures of Percentages
- Box-and-Whisker Plot
- 3. Normal Distribution
- Standard Normal Distribution Table
- References
- Chapter 20: B. Statistical Process Control (SPC)
- 1. Basic Concepts of Quality and Its Benefits
- 2. Flowchart
- 3. What Is a Process?
- 4. Check Sheet
- 5. Cause-and-Effect (Fishbone or Ishikawa) Diagram
- 6. Defect Concentration Diagram
- 7. Run Chart
- 8. Control Charts
- Preparation for Use of Control Charts
- Benefits of Control Charts
- Rational Subgroups for a Control Chart
- 9. Average Run Length
- 10. Operating Characteristic Curve
- 11. Common Causes versus Special Causes
- Process Evaluation
- Action on Process
- Action on Output
- Variation
- Common Causes, or Random Causes
- Special Causes, or Assignable Causes
- 12. Control Limits versus Specification Limits
- 13. Control Charts for Variables
- Shewhart X-bar and R Control Chart
- Calculation of Sample Statistics
- Calculation of Control Limits
- Interpretation of Shewhart X-bar and R Control Charts
- Shewhart X-bar and R Control Chart When Process Mean µ and Process Standard Deviation s Are Known
- Shewhart X-bar and S Control Chart
- Calculation of Control Limits
- 14. Control Charts for Attributes
- The p Chart: Control Chart for Fraction of Nonconforming Units
- Control Limits for the p Chart
- Interpreting the Control Chart for Fraction Nonconforming
- The p Chart: Control Chart for Fraction Nonconforming with Variable Samples
- The np Chart: Control Chart for Number of Nonconforming Units
- Control Limits for np Control Chart
- The c Chart (Nonconformities versus Nonconforming Units)
- The u Chart
- 15. Process Capability Analysis
- Process Capability Index: Cp
- Process Capability Index: Cpk
- Process Capability Indices: Pp and Ppk
- References
- Chapter 21: C. Quality Improvement
- 1. Terms and Concepts
- Prevention versus Detection
- The Importance of Customer Satisfaction
- The Cost of Poor Quality
- 2. Products and Processes
- Product
- Process
- The Interrelatedness of Products and Processes
- References
- Bibliography
- Chapter 22: D. Quality Audits
- Terms and Definitions
- 1. Types of Audits
- Roles and Responsibilities in Audits
- 2. Audit Process
- 3. Audit Tools
- Checklists
- Log Sheets
- Sampling Plans
- 4. Communication Tools and Techniques
- 5. Corrective Action Requests (CARs)
- Audit Outcomes
- Audit Reporting and Follow-Up
- References
- Bibliography
- Chapter 23: E. Quality Tools and Techniques
- Seven Basic Quality Control Tools
- Bibliography
- Chapter 24: F. Problem-Solving Tools and Continuous Improvement Techniques
- 1. Plan-Do-Check-Act (PDCA) or Plan-Do-Study-Act (PDSA) Cycles
- Plan
- Do
- Check
- Act
- 2. Lean Tools for Eliminating Waste
- 5S
- Error-Proofing
- Value Stream Mapping
- Lean Concepts
- 3. Six Sigma Phases
- The Scientific Method
- Six Sigma
- Root Cause Analysis
- 4. Failure Mode and Effects Analysis (FMEA)
- Selecting a Standard for FMEA
- Planning for an FMEA
- Establishing a Single Point of Responsibility
- FMEA Team Members
- Inputs to an FMEA
- FMEA and Other Quality Tools
- Outputs from an FMEA
- Basic Steps in an FMEA
- Quantifying the Risk Associated with Each Potential Failure
- FMEAs Encountered by Quality Professionals
- Design and Process FMEA
- Heading Information and Documentation
- Analysis Content and Documentation
- A Final Word on Taking Corrective Action
- Assessing Criticality
- A Caution about Using FMEA
- Design and Process FMEA Examples
- FMEA Summary
- 5. 8D Methodology
- 6. 5 Whys
- 7. Fault Tree Analysis (FTA)
- References
- Bibliography
- Chapter 25: G. Resources
- 1. Environmental and Safety Support
- 2. Reference Documents
- 3. Employees as Resources
- Empowering Employees
- Employee Involvement
- Team Roles and Responsibilities
- Stages of Team Development
- Conflict Resolution
- Consensus
- Brainstorming
- Meeting Management
- 4. Quality Documentation
- ISO 9001
- First Article Inspection Report (FAI)
- Initial Sample Inspection Report (ISIR)
- Production Part Approval Process (PPAP)
- Basic Quality Documentation
- References
- Bibliography
- Section V: Appendices
- Appendix A: American Society for Quality Certified Quality Inspector (CQI) Body of Knowledge 2018
- Appendix B: Computer Resources to Support the CQI Handbook
- Appendix C: General Tables of Units of Measurement
- Appendix D: Standard Normal Distribution
- Appendix E: Factors Helpful in Constructing Control Charts for Variables
- Appendix F: Values of K1 for Computing Repeatability Using the Range Method
- Appendix G: Values of K2 for Computing Reproducibility Using the Range Method
- Appendix H: Sample Tables of ANSI/ASQ Z1.4-2008 and ANSI/ASQ Z1.9-2008 Standards
- Glossary of Inspection Terms
- Index
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