Unit - I Measurement Standards and Design of Gauges Introduction : Principles of Engineering metrology, Measurement standards, Types and sources of errors, Accuracy and Precision, Calibration : Concept and procedure, traceability, Geometric Form Measurement : Straightness, Flatness, Roundness - Straight edge, use of level beam comparator, autocollimator, testing of flatness of surface plate. Design of Gauges : Tolerances, Limits and Fits [IS 919-1993], Taylor’s principle, Types of gauges, Wear allowance on gauges, Types of gauges-plain plug gauge, ring gauge, snap gauge, limit gauge and gauge materials, Considerations of gauge design (numerical). Unit - II Comparators, Thread and Gear Metrology, Surface Roughness Measurement Comparators : Mechanical, Pneumatic, Optical, Electrical (LVDT). Measurement of Thread Form : Thread form errors, Measurement of Minor, Major and Effective diameter (Three Wire Method), Flank angle and Pitch, Floating Carriage Micrometer (Numerical). Gear Metrology : Errors in Spur Gear form, Gear tooth Vernier, Constant chord, Base tangent (Numerical), Gear Rolling Tester. Profile Projector, Tool maker’s microscope and their applications. Surface Roughness Measurement : Introduction to Surface texture, Parameters for measuring surface roughness, Surface roughness measuring instrument: TalySurf. Unit - III Advances in Metrology Coordinate Measuring Machine (CMM) : Fundamental features of CMM – development of CMMs – role of CMMs – types of CMM and Applications, – types of probes Machine Vision Systems : vision system measurement – Multisensory systems. Interferometer : Principle, NPL Interferometer Laser Metrology : Basic concepts of lasers, advantages of lasers, laser interferometers, types, applications. Unit - IV Introduction to Quality and Quality Tools Concept of Quality : Various Definitions and Quality Statements, Cost of quality & value of quality, Deming’s cycles & 14 Points, Juran Trilogy approach, Old New Seven Tools, Quality Circles. Importance of Quality Deployment at Design and Manufacturing Engineering : Opportunities for improvement product design, Importance of – initial planning for quality, concept of controllability : self-controls – defining quality responsibilities on the factory flow – self inspection. Unit - V Statistical Quality Control 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 (Numerical). Production Part Approval Method (PPAP). Acceptance Sampling : Sampling Inspection, OC Curve and its characteristics, sampling methods, Sampling Plan : Single, Double (Numerical), Multiple, Comparison of Plan, calculation of sample size, AOQ, Probability of Acceptance (Numerical). Unit - VI Total Quality Management TQM : Introduction, Quality Function Deployment, 5S, Kaizen, Poka yoke, Kanban, JIT, FMECA, Zero defects, TPM. Six Sigma : DMAIC - Concept and Applications. Quality Management System : Need for quality management system – design of quality management system - quality management system requirements – ISO 9001, TS-16949, ISO-14000, Quality Audit.
