Metrology and Quality Control syllabus

Metrology Fundamentals and Modern Measurement Systems: Role of metrology in smart manufacturing and Industry 4.0, measurement standards and traceability (ISO/BIS standards), types and sources of errors, measurement uncertainty analysis, accuracy, precision, repeatability and reproducibility (R&R concept), calibration: digital calibration systems and documentation. Measurement Instruments and Comparators: Digital instruments such as Vernier caliper, micrometer and height gauge, Types of gauges-plain plug gauge, ring gauge, snap gauge, limit gauge and gauge materials comparators: mechanical, pneumatic and electrical (LVDT). Limits, Fits and Geometric Tolerance: Limits, fits and tolerances, Introduction to Geometric Dimensioning and Tolerance (GD&T) symbols and industrial applications. CCE Activities: Measurement of dimensions of given components using digital instruments such as Vernier calliper, micro meter, height gauge, and dial gauge

Coordinate Measuring Machines (CMM): Types of CMM such as bridge, gantry, portable and horizontal arm, types of probes including touch trigger, scanning and optical probes, applications in reverse engineering and inspection. Optical and Non-Contact Metrology: Machine vision systems including image processing basics and industrial inspection applications, profile projector and toolmaker’s microscope, 3D scanning technologies such as laser scanning and structured light. Thread and Gear Metrology: Thread parameters such as major diameter, minor diameter and pitch diameter, introduction to optical and CMM-based thread measurement, gear metrology including gear errors Surface Metrology: Surface texture and parameters such as Ra, Rz and Rt, modern surface measuring instruments including stylus-based instruments, optical surface profilers.

Introduction to Quality: Quality Concepts, Quality dimensions, Statements, Cost of quality & value of quality, Deming‟s cycles & 14 Points, Juran Trilogy approach, Seven Quality Tools, Introduction to New Seven Tools, Quality Circle, 5S, Kaizen, Poka yoke, Kanban, JIT, QMS (ISO 9000, TS16949, ISO14000). Criteria for Quality Award (National & International)

Statistical quality control: Statistical concept, Frequency diagram, Concept of variance analysis, Control, Chart for Variable (X & R Chart) & Attribute (P & C Chart), Process capability (Indices: cp, cpk, ppk), Statistical Process Control and six sigma. Acceptance Sampling: Sampling Inspection, OC Curve and its characteristics, sampling methods, Sampling Plans, calculation of sample size, AOQ, Probability of acceptance. (Numerical on control charts and sampling)

Advanced Quality Tools: Failure Mode and Effects Analysis (FMEA), Failure Mode, Effects and Criticality Analysis (FMECA), steps involved in FMEA, Risk Priority Number (RPN), severity, occurrence and detection ratings, basic symbols, and case studies. Lean and Six Sigma Integration: Overview of Six Sigma (DMAIC methodology), introduction to Lean principles, waste identification and integration of Lean and Six Sigma for process improvement. Digital Quality and Industry 4.0: Introduction to digital quality management systems, real-time quality monitoring, application of IoT in quality control, and concepts of smart inspection and data-driven decision making.