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Module 1: Introduction to Quality Control in Mechanical Engineering
• Overview of Quality Control (QC): History and importance in mechanical engineering.
• Quality Concepts and Terminology: Definitions like quality assurance, quality control, and inspection.
• Role of a QC Engineer: Responsibilities and career outlook in mechanical engineering.
Module 2: Quality Standards and Certifications
• Introduction to Quality Standards: ISO 9001, Six Sigma, and AS9100.
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• International vs. Local Standards: Differences in requirements and application.
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• Certification Process: Understanding the procedures for achieving and maintaining certifications.
Excel Format For Certification Process Management
Module 3: Statistical Quality Control (SQC)
• Fundamentals of Statistics in QC: Mean, variance, standard deviation.
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• Control Charts: Types (X-bar, R-chart, P-chart, etc.) and interpretation.
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• Process Capability Analysis: Cp, Cpk metrics, and their role in quality improvement.
Module 4: Inspection Methods
• Visual and Manual Inspection: Techniques and tools (calipers, micrometers, etc.).
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• Non-Destructive Testing (NDT): Ultrasonic, radiographic, magnetic particle, and liquid penetrant methods.
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• Dimensional and Geometrical Tolerances: How to measure and ensure precision.
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Module 5: Quality Planning and Documentation
• Quality Planning Process: Steps from design to implementation.
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• Quality Control Plans (QCP): How to create and manage them.
Quality_Control_Plan_Template
• Documentation and Reporting: Importance of traceability and documentation in QC.
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Module 6: Root Cause Analysis and Problem Solving
• Failure Modes and Effects Analysis (FMEA): Identifying potential failure points.
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• Fishbone Diagrams and 5 Whys: Root cause analysis techniques.
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• Corrective and Preventive Actions (CAPA): Procedures to address and prevent defects.
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Module 7: Quality Improvement Tools and Techniques
• Lean Manufacturing: Concepts like 5S, Kaizen, and waste reduction.
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• Six Sigma in QC: Tools like DMAIC, DMADV, and statistical analysis.
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• Continuous Improvement Models: Plan-Do-Check-Act (PDCA) cycle.
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Module 8: Quality Control in Manufacturing Processes
• Machining Processes: CNC, casting, welding, and assembly QC practices.
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• Quality in Supply Chain Management: Supplier quality control and audits.
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• Advanced Manufacturing Technologies: 3D printing, automation, and their impact on QC.
Advanced_Manufacturing_QC_Excel_Sheets
Module 9: Quality Audits and Compliance
• Internal vs. External Audits: Procedures, roles, and importance.
• Audit Preparation: Key steps to prepare for a QC audit.
QC_Audit_Preparation_Excel_Sheets
• Compliance with Regulations: Understanding mechanical industry-specific regulations.
Mechanical_Industry_Compliance_Excel_Sheets
Module 10: Software Tools for Quality Control
• Popular QC Software: Tools like Minitab, SPC, and others.
• Data Management in QC: How to collect, store, and analyse data effectively.
• Automating QC Processes: Role of technology in improving QC efficiency.
Module 11: Case Studies and Industry Applications
Module 11: Case Studies and Industry Applications
• Interactive Workshops: Exercises focused on solving quality-related issues.
• Industry Applications: QC practices in aerospace, automotive, heavy machinery, and energy sectors.
Module 12: Final Assessment and Project
• Capstone Project: Applying QC techniques to a real or simulated mechanical engineering project.
• Final Exam: Testing the knowledge gained throughout the course.