Managing the Metrology System

C. Robert Pennella

Description

The proper application of a calibration system is one of the most important areas in which quality-assurance personnel can positively affect the low quality high costs associated with poorly manufactured products. Learn how to implement an effective calibration system, one that can be the foundation of your organization’s inspection systems and quality programs. This book provides an easy to understand explanation of metrology systems and is updated to reflect the ANSI/ISO/ASQC Q9000 standards. Technicians can increase their ability to maintain instruments of known accuracy and case studies help you understand exactly how to apply the book's principles.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Sciences formelles
• Mathématiques appliquées
• Mathématiques appliquées
• Techniques
• Automatisation et Contrôle
• Contrôle des processus
• Automatisation
• Automate
• Sciences et techniques
• Metrology
• Measurement
• Mathematics
• MSA

Informations

• Publié par: ASQ Quality Press
• Date de parution: 03 janvier 2004
• Nombre de lectures: 0
• EAN13: 9780873898249
• Langue: English

Extrait

Managing the Metrology System

Third Edition

Also available from ASQ Quality Press:

The Uncertainty of Measurements: Physical and Chemical Metrology: Impact and Analysis S. K. Kimothi

Failure Mode and Effect Analysis: FMEA from Theory to Execution,Second Edition D. H. Stamatis

HALT, HASS, and HASA Explained: Accelerated Reliability Techniques Harry W. McLean

Concepts for R&R Studies,Second Edition Larry B. Barrentine

The Desk Reference of Statistical Quality Methods Mark L. Crossley

The Certified Quality Engineer Handbook Donald W. Benbow, Roger W. Berger, Ahmad K. Elshennawy, and H. Fred Walker, editors

To request a complimentary catalog of ASQ Quality Press publications, call [phone], or visit our Web site at http://qualitypress.asq.org.

Managing the Metrology System

Third Edition

C. Robert Pennella

ASQ Quality Press Milwaukee, Wisconsin

American Society for Quality, Quality Press, Milwaukee 53203 ©1992, 1997, 2004 by ASQ All rights reserved. Published 1992. Third Edition 2004. Printed in the United States of America 12 11 10 09 08 07 06 05 04 5 4 3 2 1

Library of Congress Cataloging-in-Publication Data Pennella, C. Robert. Managing the metrology system / C. Robert Pennella.—3rd ed. p. cm. Includes bibliographical references and index. ISBN 0-87389-606-8 (acid-free paper) 1. Engineering inspection. 2. Mensuration. 3. Quality control. I. Title. TS156.2.P46 2003 658.5'68—dc22 2003016816

ISBN 0-87389-606-8 No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Publisher: William A. Tony Acquisitions Editor: Annemieke Hytinen Project Editor: Paul O’Mara Production Administrator: Barbara Mitrovic Special Marketing Representative: Robin Barry ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange. Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, videotapes, audiotapes, and software are available at quantity discounts with bulk purchases for business, educational, or instructional use. For information, please contact ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, P.O. Box 3005, Milwaukee, WI 53201-3005. To place orders or to request a free copy of the ASQ Quality Press Publications Catalog, including ASQ membership information, call 800-248-1946. Visit our Web site at www.asq.org or http://qualitypress.asq.org.

Printed on acid-free paper

To my wife Anita. Thanks for the understanding, support, and love.

In memory of Pasquale J. Di Pillo, PhD, fellow, colleague, educator, mentor, and advocate of the American Society for Quality 1934–2003

Table of Contents

List of Figures and Tables . . . . . . . . . . . . . . . . . . . . . Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 Calibration System Description . . . . . . . . . . . . Chapter 3 Metrology Audit . . . . . . . . . . . . . . . . . . . .

Chapter 4 Case Study 1—Supplier with Unknown Calibration System Capabilities . . . . . . . . . . . . . . . . .

Chapter 5 Communicating Calibration Capabilities: Using Effective Documentation . . . . . . . . . . . . . . . . .

Chapter 6 Case Study 2—Supplier’s Calibration System: An Integral Part of an ANSI/ISO/ASQ Q9000 Quality System Manual . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 Costs Associated with Metrology Systems Management . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 8 Self-Assessment of Metrology Systems . . . . . . . . Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

viii x 1 15 49

67

79

97

125 141 199 205 207 209

List of Figures and Tables

Figure 2.1 Figure 2.2 Figure 2.3 Figure 2.4 Figure 2.5

Figure 2.6

Figure 2.7 Figure 2.8 Figure 2.9 Figure 2.10 Figure 2.11 Table 2.1 Figure 2.12 Figure 2.13 Figure 2.14 Figure 2.15

Table 2.2 Figure 2.16 Figure 2.17 Figure 2.18 Figure 2.19 Figure 2.20

Figure 3.1 Figure 3.2

Figure 3.3

Figure 3.4 Figure 3.5

Figure 3.6

A typical organizational structure. . . . . . . . . . . . . . Master requirements list. . . . . . . . . . . . . . . . . . . Instructions for preparing the master requirements list. . . Measuring equipment recall/ location record form. . . . . . Instructions for preparing the measuring equipment recall/ location record form. . . . . . . . . . . . . . . . . . Steps that lead to the application of required calibration procedures. . . . . . . . . . . . . . . . . . . . Calibration procedure form. . . . . . . . . . . . . . . . . . Instructions for preparing calibration procedures. . . . . . A sample calibration procedure—keyboard functions. . . . Product tolerance in a unilateral direction. . . . . . . . . . Product tolerance in a bilateral direction. . . . . . . . . . . Impact of accuracy ratios. . . . . . . . . . . . . . . . . . . Example of a 1:1 accuracy ratio. . . . . . . . . . . . . . . Example of a 4:1 accuracy ratio. . . . . . . . . . . . . . . Example of a 10:1 accuracy ratio. . . . . . . . . . . . . . Representative curve for a product tolerance of 0.001". . . . . . . . . . . . . . . . . . . . . . . . . . . Accuracy ratios between product tolerance and M&TE. . . An example of a manufacturer’s calibration record. . . . . A sample certificate of inspection. . . . . . . . . . . . . . NIST report of calibration. . . . . . . . . . . . . . . . . . Metrology deficiency report. . . . . . . . . . . . . . . . . Instructions for preparing the metrology deficiency report. . . . . . . . . . . . . . . . . . . . . . . Calibration system checklist for calibration intervals. . . . Calibration system checklist for out-of-tolerance conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration system checklist for calibration system requirements. . . . . . . . . . . . . . . . . . . . . Calibration system checklist for MS adequacy. . . . . . . Calibration system checklist for environmental controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration system checklist for calibration procedures. . . . . . . . . . . . . . . . . . . . . . . . . .

viii

19 21 22 25

2

6

27 28 28 30 31 31 33 34 35 36

37 37 38 39 41 43

44 52

5

3

53 54

5

5

5

5

Figure 3.7 Figure 3.8

Figure 3.9 Figure 3.10

Figure 3.11

Figure 3.12 Figure 3.13 Figure 3.14 Figure 3.15 Figure 3.16

Figure 3.17 Figure 3.18

Figure 3.19 Figure 3.20

Figure 4.1 Figure 4.2 Figure 4.3 Figure 5.1 Figure 5.2

Figure 5.3 Figure 5.4 Figure 5.5 Figure 5.6 Figure 5.7 Figure 5.8 Figure 5.9 Figure 5.10 Figure 5.11 Figure 5.12 Figure 5.13 Figure 6.1 Figure 6.2 Figure 7.1 Figure 7.2 Figure 7.3 Figure 7.4

List of Figures and Tables

Calibration system checklist for calibration sources. . . . . Calibration system checklist for application of records. . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration system checklist for calibration status. . . . . . Calibration system checklist for control of subcontractor calibration. . . . . . . . . . . . . . . . . . . Calibration system checklist for purchaser- supplied M&TE. . . . . . . . . . . . . . . . . . . . . . . Calibration system checklist for storage and handling. . . . Calibration system checklist for inventory control. . . . . . Calibration system checklist for capabilities. . . . . . . . . Calibration system checklist for sealing for integrity. . . . Calibration system checklist for traceability of documentation. . . . . . . . . . . . . . . . . . . . . . . Calibration system audit summary report (external). . . . . Instructions for completing the audit summary report (external). . . . . . . . . . . . . . . . . . . . . . . Calibration system audit summary report (internal). . . . . Instructions for preparing the calibration system audit summary report (internal). . . . . . . . . . . . . . . Abstract of solicitation requirements. . . . . . . . . . . . . Pre-award survey report. . . . . . . . . . . . . . . . . . . Milestone chart calibration system requirements. . . . . . Abstract of contract quality requirement. . . . . . . . . . . Master requirements list, number one, drawing ABC-123. . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration equipment list. . . . . . . . . . . . . . . . . . Calibration procedure for micrometer, 1–2 inches. . . . . . Calibration procedure for micrometer, 0–1 inch. . . . . . . Calibration procedure for dial indicator. . . . . . . . . . . Calibration procedure for “go/not go” plug gage. . . . . . Calibration procedure for vernier caliper. . . . . . . . . . . Sample observation record of production inspection. . . . Abstract of solicitation requirements. . . . . . . . . . . . . Metrology deficiency report. . . . . . . . . . . . . . . . . Sample calibration record of M&TE. . . . . . . . . . . . . Nonconforming material report. . . . . . . . . . . . . . . Signatures of key quality management personnel. . . . . . Record of employee training. . . . . . . . . . . . . . . . . Impact of lengthened calibration intervals. . . . . . . . . . Percent of yearly costs when intervals arelengthened.. . . Impact of shortened calibrationintervals.. . . . . . . . . Percent of yearly costs when intervals areshortened. . . .

ix

57

58 58

5

8

59 59 59 60 60

60 61

62 63

64 70 71 72 80

82 83 85 86 87 88 89 90 92 93 94 95 103 123 129 130 130 131