Industrial Engineering and Quality Control Course Code: 22657

Program Name : Diploma in Mechanical Engineering

Program Code : ME
Semester : Sixth
Course Title : Industrial Engineering and Quality Control
Course Code : 22657

1. RATIONALE
In any mechanical industry, industrial engineering integrates men, machines, materials,
method of production, information, and energy to make a product and hence enhance
productivity by eliminating wastefulness in production processes. Mechanical engineering
technologists needs to determine the standardized process, time for its completion known as
work and time study, measuring the output in terms of productivity, evaluation of j obs,
workers and determining the wages and incentives, measurement of quality of product. Total
Quality Control is an effective system of integrating quality development, quality
maintenance and quality improvement efforts of the various groups in industry, so as to
enable production and services at most economical level which tends towards full customer
satisfaction. Understanding of fundamental principles of industrial engineerin g and quality
control helps a technologists in maximizing efficiency within a company by finding the best
use of people, equipment, and facilities..

2. COMPETENCY
The aim of this course is to help the student to attain the following industry identified
competency through various teaching learning experiences:
• Apply Industrial Engineering and Quality Control techniques for assuring
quality of products and services.

3. COURSE OUTCOMES (COs)

The theory, practical experiences and relevant soft skills associated with this course are to be
taught and implemented, so that the student demonstrates the following industry oriented
COs associated with the above mentioned competency:
a) Apply work study techniques to optimize manufacturing processes.
b) Prepare the detailed sequence of operations for manufacturing of components.
c) Apply Ergonomic principle for designing simple mechanical component .
d) Interpret the data obtained from the different quality control processes.
e) Interpret control charts for variable and attribute data.

4. TEACHING AND EXAMINATION SCHEME

Teaching
Examination Scheme
Scheme
Credit
Theory Practical
L T
(L+T+P)
Paper ESE PA Total ESE P A Total
Hrs. Max Min Max Min MaxFVIin Max Min Max Min Max Min
3 70 28 30* 00 100 40 25# 10 25 10 50 20

(*): Under the theory PA, Out of 30 marks, 10 marks are for micro project assessment to
facilitate integration of COs and the remaining 20 marks is the average of 2 tests to be taken
during the semester for the assessment of the cognitive domain UOs fegiii iwi for the
attainment of the COs.

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 Industrial Engineering and Quality Control Course Code: 22657

Legends: L-Lecture; T — Tutorial/Teacher Guided Theory Practice; P - Practical; C — Credit,

ESE - End Semester Examination; PA - Progressive Assessment
5. COURSE MAP (with sample COs, PrOs, UOs, ADOs and topics)
This course map illustrates an overview of the flow and linkages of the topics at various levels
of outcomes (details in subsequent sections) to be attained by the student by the end of the
course, in all domains of learning in terms of the industry/employer identified competency
depicted at the centre of this map.
.....•"- . . , . . . . . . . .

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\%. rem laced/el. ..." •
4•?•••• • . •••"/
. . . —..
 • • • • • - . . . • - -. - • -------------- - - - ,
 •- ... _ _ ....
. " T o p i c 5 . 2 C o n u o l . c l u t r t .
: - inherent and assignable *. .................
I., sources of variation. .

--....'"•' ................. '

...... • —.., • ....,. • 1 . • ' • .,.
'•,,, • Topic - 3.1 lirgonumics- ".., •
 I D S c - I n t e r p r e t t h e '• . Concept, need. min- ".
 .,
 1 . .■ i went:4 clouts 0: & it•bar. i - - _ _ , ...... , machine relationship.
anthropornetric etc .:
..*
',
..._.... „, - -- - • P . ch tu t an d C - cla t ut l ti n
, ' ' ' ' • m e a s u r e d l i r a s o f t h e s i r e n , , . • ., - -
., .... ............ . , ,
'• ..... . ....... ':•
,• ... V --

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..„ 4.. A
 _ _ _ - ......... ... ts
* Pr° 1 7- R e design th e ". , •, r
'0, • .• • , •-• - - ..tivoi 9impic ..
A, 1 1.
A
' s* PrOl 9- Draw. and *., '

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, • elinris (.X hal and .  . ,.. ,
; Interptel the t:aiiirgl I,
tt ..,,,, • / • -•••••• :%
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4- Apply work 1..
i
fromIcricy polygon 1 i
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r•
:
le (-0 (d)- Anaiy lbeN •i 
e
. .,, % 1,,I the Samples i CO 04 -Pre pare the I •
semi-en-co of opera] Mot 1 '.. IT,l oil: ::Iini ptmc 71.1,
Im a144 cpm ::1
:.,/ •• r, s •. data ttlivained Mini ) • ....--
r s ... 4
,,o
/
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i
,
control prow-ues. . numufactuting of I
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f Sequence nfoperation far . . tiO lh - Plait appropriate '••• ; ...." ,
1
. , et)flditi0.
,..'. Topic 4.2- Total Quality *•.- - '. manufacitu ing ors jerk .._: g :NI tkuracturing proces,t, . •• 13b
.. ohjectives. •
 tin Manufacturirm of 1 •,, procedure, selection . 1 .••••
• Management : ....„, ... •.. " V I /
........
 S I N 5 i t t i n a : S t a. t i s i r c a l - -4` - ........................... . ... _ _N I, . simple component.
. .k
... itte.iting ire. methodology •••  .. .. _ _ fricnthet for comfort o' . , ; J.
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O e , ••4, • ' ' .4.4.'' ' I 1
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/ ( - 0 ( C ) - I n te r ptiA / CO (ay Apply ssock N\ 'I% - . t .

1 / UO •Id - Identify • . . . .
i conii 01 aunts for f study techniques to X \

I• 'Key its signs roles, ... 1 V1LT'obis! ski 0,,ma..15.1 I I., / - ••••• '
(JO IA-
•
Apply ‘ :
Apply Imittstrhil Erieg. mid ' it, ,,,,iiiiii. mann f.
'I ll sit si.ama strategic '. peocess. / ,. method runty for ' I
i• group, etc i \ attribute data. Quality Control techniques ntamilwuring. or I:
/ far assuring quality of ‘1/4
••••

Tapir ProeesS ,-
.. " - - - - •
_.• Engineering- functions- ....- -
preliminary part pri11
.... analysis
....
..• ................ ...
Legends
.......„.. ......... _ .............. ,..... ,... ............. ...,,
, . • - .
-.

, .. .... •• un!ip CopitIvc • .." ADO.Affeethe

1 CO • Cott ne ()moire ,i ; •
Pr{] through Practical's •
-": f i )
i. ., • z .
,.• N. f l o r e u t i n . 1.kmaiii Outcome Topic
.. .. .,
....'" \. . ...," ' '''•- .................. .../
............................

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Figure 1 - Course Map
Industrial Engineering and Quality Control Course Code: 22657

6. SUGGESTED PRACTICALS/ EXERCISES

The practicals in this section are PrOs (i.e. sub-components of the COs) to be developed and
assessed in the student for the attainment of the competency.

Approx.
S. Unit
Practical Outcomes (PrOs) Hrs.
No. No.
Re I uired
1 Apply method study approach Analyze the motions involved in I 02*
machining operation of the given job

2 Apply work measurement technique to analyze the time I 02*

components involved machining operation of given job using stop
watch.
3 Calculate standard time for all the operations involved in step I 02
turning process.
4 Prepare motion chart of given activity using standard symbols of I
02
therbli s (max 18).
5 Prepare supply chain chart in day-to-day situation like supply of II 02*
Cold drink/tooth paste/an rocery item.
6 Prepare supply chain management chart for online purchase of II 02
roods/products.
7 Prepare detailed process plan for manufacturing of Hexagonal II 02*
Nut/Hexagonal headed bolt/Stud/Wing Nut/Plain Washer.
8 Prepare chart of Sequence of operation for manufacturing of simple II 02
job
like manufacturing of hexagonal nut & bolt/ Manufacturing of V-
Block on shaper machine.
9 Prepare Chart of sequence of operation for Single or Double II
02*
riveted lap joint/Single riveted butt joint (single strap).
10 Use Ergonomic principle for given component . III 02*
11 Prepare and analyze steps to solve the given problem in IV
02*
institute/industry using quality circle concept.
12 Draw the frequency histogram, frequency polygon for the samples V
02
and calculate mean, mode and median for same.
13 Draw the normal distribution curve, calculate Deviation, Variance, V
02*
Range and determine the process capability for -I-3a or -I- 6a.
14 Draw and interpret the control charts (Xbar and R) for given data. V 02
15 Draw and interpret the control charts ( P-chart and C-chart) for V
02*
given data.
Total 30

Note
i. A suggestive list of PrOs is given in the above table. More such PrOs can be added to
attain the COs and competency. A judicial mix of minimum 12 or more practical need to be
performed, out of which, the practicals marked as are compulsory, so that the student
reaches the 'Precision Level ' of Dave 's 'Psychomotor Domain Taxonomy' as generally
required by the industry.
ii. The 'Process' and 'Product' related skills associated with each jx to be assessed
according to a suggested sample given below:

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.

4
Industrial Engineering and Quality Control Course Code: 22657

S.No. Performance Indicators Weightage in %

Preparation of experimental set up 20
2 20
S et t i n g and op er at i on
3 Safety measures 10
4 Observations and Recording 10
5 Interpretation of result and Conclusion 20
6 Answer to sample questions 10
7 Submission of report in time 10
Total 100

The above PrOs also comprise of the following social skills/attitudes which are Affective
Domain Outcomes (ADOs) that are best developed through the laboratory/field based
experiences:
a) Follow safety practices.
b) Practice good housekeeping.
c) Practice energy conservation.
d) Work as a leader/a team member.
e) Follow ethical practices.

The ADOs are not specific to any one PrO, but are embedded in many PrOs. Hence, the
acquisition of the ADOs takes place gradually in the student when s/he undertakes a series of
practical experiences over a period of time. Moreover, the level of achievement of the ADOs
according to Krathwohl's 'Affective Domain Taxonomy' should gradually increase as planned
below:
 'Valuing Le vel' in P l year
 'Organisation Level' in 2" year
 'Characterisation Level' in 3 rd year.

7. MAJOR EQUIPMENT/ INSTRUMENTS REQUIRED

The major equipment with broad specification mentioned here will usher in uniformity in
conduct of experiments, as well as aid to procure equipment by authorities concerned.

S. Equipment Name with Broad Specifications PrO. No.

No.
Stop Watch Timing capacity:23hrs, 59mins and 59.99secs, Accuracy: ±3
1, 2,3,4,5,
seconds/day
Digital Video Camera for Micro Motion Analysis with following 1, 2,3,4,5,
specification (i) ISO 100-12800 (ii) Focal length f = 3.5-5.6 (iii) 24.2 MP
(iv) lenses 18-55mm.
4,5,6
Steel Rule for Length Measurement Range 0-5 feet ,10,11.12
10,11,12
Digital/manual Vernier Caliper Range 0-150 mm, L.C. 0.02mm 10,11,
5 Digital / manual Screw thread Micrometer, Range 0-25 mm, L.C. 0.01 mm 10,11,
6 Digital / manual Screw Thread Micrometer Range 25-50mm, L.C. 0.01mm 13.14.15
7 Display Wall chart showing X bar Chart and R CHART 13,14,15
8 Display Wall chart showing "C Chart" 7
9 Display Wall chart showing Therbilgs with minimum 18 symbols
10 Standard samples like steel balls, bearings, turning operation jobs, bear 13,14,15
samples for sample measurement
11 Different types of Ergonomic Charts

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*
Industrial Engineering and Quality Control Course Code: 22657

8. UNDERPINNING THEORY COMPONENTS

The following topics are to be taught and assessed in order to develop the sample UOs given
below for achieving the COs to attain the identified competency. More UOs could be added.

Unit Unit Outcomes (UOs) Topics and Sub-topics

Unit— I (in cognitive domain) 1.1 Industrial Engineering: Definition,
Work Apply method study for Need, Objectives and Scope
Study manufacturing of the given 1.2 Work study: Method study(Motion
(Method job. Study) and Time study(Work
Study Apply time study for Measurement)
and manufacturing of the given 1.3 Method study: Definition, objectives,
Work job. procedure, selection of work
Measure Select relevant recording 1.4 Recording Techniques: - Process
ment) techniques for the given Charts — Outline process chart, Flow
process with justification. process chart, Two Handed process
Prepare relevant types of chart/Simo Chart, multiple activity
charts for the given process Chart, Flow diagram, String diagram,
using the given recording Therbligs, Travel chart.
techniques. 1.5 Work Measurement — Objectives,
1 e. Calculate standard time for the procedure, Time Study, Time Study
given activity using work Equipment. Stop Watch Time Study,
measurement. Allowances, Calculation of Standard
Time.

Unit— II
2.1 Production: Concept, factors of
Process
production, Supply Chain Management,
Engineeri
ng 2.2 Process Engineering- functions,
preliminary part print analysis,
Selecting and planning manufacturing
process; determining manufacturing
sequence
2.3 Line Balancing: Heuristic approach of
line balancing
2.4 Critical Path Method (CPM) and its
application related to Project
completion.

Unit-III 3.1 Ergonomics- Concept, need, man-

Ergonomi
machine relationship, anthropometric
es
and functional anatomy data,
3.2 Ergonomic in design of control members
— push button, knobs, levers, cranks,
hand wheel.
3.3 Ergonomic considerations applied to
r--
 3a Apply of
2a Apply principles ergonomic
supply concept to
improve
chain management working
in the given conditions
in the given industrial
industrial/domestic
application. environment(s).
3b Apply ergonomics principle
2b Plan appropriate
manufacturingtoprocesses
given simple
for component.
3c Use
manufacturing ergonomic
of the given principle for
simple job/component.
2c Sketch precedence diagram for
the given simple
manufacturing task using line
balancing concept.
2d Apply CPM for the given
project of the specified
industry.
2e Prepare the detailed sequence
of operations for
manufacturing the given
component.

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Industrial Engineering and Quality Control Course Code: 22657

Unit Unit Outcomes (UOs) Topics and Sub-topics

(in cognitive domain)
types and location of display.
designing different controls 3.4 Compatibility in the design of control
and displays members.

Unit —IV 4a Prepare quality characteristics 4.1 Meaning of quality of produce and
Quality chart which contribute to fitness services, Quality characteristics, Quality
Control for use of the given job/ of design, Quality of conformance,
component. Quality of performance, Concept of
and
4b List steps to solve the given reliability, Cost, Quality assurance, Cost
Inspectio problem in the industry using of rework and repair, Quality and
quality circle concept with Inspection, Quality Circle
justification.
4.2 Total Quality Management; Six sigma:
4c Identify Key six sigma roles , Statistical meaning and methodology,
six sigma strategic group, Six sigma Black Belt concept. KAIZEN,
Master Black Belt and Black POKA-YOKE, 5S Techniques.
4.3
Belt as coaches for the given 4.4 Introduction of ISO 9000, ISO-
industrial situation. 14000. 4.5 Quality Economics: Cost
4d Prepare cause and effect of quality,
diagram/ Pareto chart/Scatter Value of quality, Economics of quality
diagram for solving the given confirmation, Cost of quality appraisal,
problem for root cause analysis. prevention, external and internal failure
4e Select the type of inspection to cost. Quality function deployment:
be carried out at various stages Basic concept and areas of application.
of process/ product layout for 4.6 Various Q-C tools: Cause-and-effect
the given situation relevant to diagram (fishbone or Ishikawa
industry with justification. diagram),Check sheet, Histogram,
4f Interpret the data obtained Pareto chart and Scatter diagram. 4.7
from the given quality control Inspection Definition and meaning,
processes. Difference between Inspection and
5a Calculate mean, mode quality control, Classification of
and median for the given Inspection —(i) Process Inspection (ii) Final
sample(s) including the Inspection (iii) Raw Material
frequency histogram, (finished/semifinished) Inspection (iv) Tool
frequency polygon. and Gauge Inspection. Role of Quality Control
5b Represent the given Inspectorisupervisor. 5.1 Basics of Statistical
data through normal concepts, Meaning
Unit-V
distribution curve after and importance of SQC.
Statistica
calculating the standard 5.2 Variable and attribute Measurement.
I Quality
deviation (a), variance, range Control charts — inherent and assignable
Control
to determine the process sources of variation. Control charts for
capability.
variables — X and R charts, control
5c Interpret the control charts (X charts for attributes p, np, C charts.
and R-bar, P-chart and C- 5.3 Process capability of machine (±36 or
chart) for measured data of the ± 66), Cp and Cpk calculations.
given sample(s). 5.4 Acceptance Sampling
5d Prepare Single/Double
Concept, Comparison with 100%
inspection, 0 • Characteristics
Curve,
5.5 Di ift_Tent types of sampling, plans,
sampling methods.

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Industrial Engineering and Quality Control Course Code: 22657

Unit Outcomes (UOs) Topics and Sub-topics

(in cognitive domain)
sampling plan for the
given 5.6 Merits and demerits of acceptance
Lot size (N), Sample size(n), sampling.
acceptance number(c)
5e. Interpret control charts for the given variable and attribute data.

Note: To attain the COs and competency, above listed UOs need to be undertaken
to achieve the 'Application Level' and above of Bloom's 'Cognitive Domain Taxonomy'

9. SUGGESTED SPECIFICATION TABLE FOR QUESTION PAPER DESIGN

Unit Unit Title Teaching Distribution of Theory Marks
No. Hours R U A Total
Level Level Level Marks
Work Study (Method Study and
Work Measurement) 12 02 04 06 12
II Process Engineering 08 02 04 06 12
III Ergonomics 06 02 04 06 12
IV Quality Control and Inspection 10 02 04 10 16
Statistical Quality Control 12 02 04 12 18
Total 48 10 20 40 70

Legends: R=Remember, U=Understand, A=Apply and above (Bloom's Revised taxonomy)

Note: This specification table provides general guidelines to assist student .for their learning
and to teachers to teach and assess students with respect to attainment of UOs. The actual
distribution of marks at different taxonomy levels (of R, U and A) in the question paper may
vary from above table.

10. SUGGESTED STUDENT ACTIVITIES

Other than the classroom and laboratory learning, following are the suggested student -related
co-curricular activities which can be undertaken to accelerate the attainment of the various
outcomes in this course: Students should conduct following activities in group and prepare
reports of about 5 pages for each activity, also collect/record physical evidences fo r their
(student's) portfolio which will be useful for their placement interviews:
a) Collect examples related to improvements which can be implanted in manufacturing
using concepts of ergonomics.
b) Explain with suitable examples of your choice interaction between human and
machine (any machine). Explain the procedure of evaluation of this interaction w.r.t.
ergonomics.
c) Prepare Wall Chart of 3 Sigma and Six Sigma Curves and Compare number of
defectives/rejection in parts per million (PPM).
d) Prepare list of National/international industries working on principle of Six Sigma
Technique.
e) Visit any production industry. Collect the actual data from production and quality
control department. Calculate mean, mode and median for the collected data.
f) Prepare a wall chart using standard 18 Therblings, state meaning of each symbol

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 Industrial Engineering and Quality Control Course Code: 22657

11. SUGGESTED SPECIAL INSTRUCTIONAL STRATEGIES (if any)

These are sample strategies, which the teacher can use to accelerate the attainment of the
various outcomes in this course:
a) Massive open online courses (MOOCs) may be used to teach various topics/sub
topics.
b) in item No. 4 does not mean only the traditional lecture method, but different types of
teaching methods and media that are to be employed to develop the outcomes.
c) About 15-20% of the topics/sub-topics which is relatively simpler or descriptive in
nature is to be given to the students for self-directed learning and assess the
development of the COs through classroom presentations (see implementation
guideline for details).
d) With respect to item No.10, teachers need to ensure to create opportunities and
provisions for co-curricular activities.
e) Guide student(s) in undertaking micro-projects.
f) Before starting practical, teacher should demonstrate the working of instrument.
g) Instructions to students regarding care and maintenance of measuring equipments.
h) Show video/animation films to explain functioning of various measuring Instruments
i) Teacher should ask the students to go through instruction and Technical manuals of
instruments

12. SUGGESTED MICRO-PROJECTS

Only one micro project is planned to be undertaken by a student that needs to be assigned to
him/her in the beginning of the semester. In the first four semesters, the micro -project are
group-based. However, in the fifth and sixth semesters, it should be preferably be individually
undertaken to build up the skill and confidence in every student to become problem solver so
that s/he contributes to the projects of the industry. In special situations where groups have to
be formed for micro-projects, the number of students in the group should not exceed three.
The micro-project could be industry application based, internet-based, workshop-
based, laboratory-based or field-based. Each micro-project should encompass two or more
COs which are in fact, an integration of PrOs, UOs and ADOs. Each student will have to
maintain dated work diary consisting of individual contribution in the project work and give a
seminar presentation of it before submission. The total duration of the micro-project should not
be less than 16 (sixteen) student engagement hours during the course. The student ought to
submit micro-project by the end of the semester to develop the industry oriented COs.
A suggestive list of micro-projects are given here. Similar micro-projects could be
added by the concerned faculty:
a) Calculate the predermine time and total time required for the delivery of food
(pizza/Burger) from fast food centers available in your city or town. Prepare sequence
of activity and represent with Therbligs.
b) Prepare the list on World class industries using Six sigma Technique at present. and
write detail report on any one of industry.
c) Visit any manufacturing Industry and observe analyse actual Quality Control
practices.
d) Visit any manufacturing local/nearby Industry and observe the working of type of
inspection practices carried out and prepare a report.
e) Visit any manufacturing local/nearby Industry and observe the various statistical
Quality controls techniques carried out. Prepare related chart.
0 Visit any manufacturing local/nearby Industry and observe the various sampling plan
followed by the industry. Draw the same sampling plan.

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Industrial Engineering and Quality Control Course Code: 22657

13. SUGGESTED LEARNING RESOURCES

S
' Title of Book Author Publication
No.
1 Oil Hydraulic system- Majumdar, S.R Tata McGraw Hill, New Delhi,
Principles and maintenance (2002), ISBN: 9780074637487
2 Industrial Engineering and Khanna, O.P. Dhanapat Rai Publications(P) Ltd.,
management New Delhi, (1980),
ISBN-10: 818992835X
3 Statistical Quality Control Mahajan, M. Dhanpat Rai and Sons, New Delhi,
(2006) ISBN-10: 817700039X
4 Statistical Quality Control Montgomer,y Wiley India Pvt. Ltd., New Delhi,
Douglas C. (2009), ISBN:9781118146811
5 Total Quality Management Besterfield, Pearson New Delhi, (2011)
Dale, H. ISBN-13: 9780130993069
6 A Guide to the Ergonomics Heylander, East West Press, Taylor and Fransis,
of Manufacturing Martin UK, (1997) , ISBN 0748401229
7 Ergonomics : Man in his Chhapman and Hall Ltd., U.S.A.
Murrell, K . F.
Working Environment : (2012), ISBN 13: 9780412219900
8 Oborn, David John Wiley and Sons, New York ,
Ergonomics at Work
J. (1982), ISBN-10: 0471909424
Ralph, M. John Wiley and Sons, UK, (2009),
Motion and Time Studies
Barnes ISBN-9788126522170
10 Hand Book of Industrial Gavriel, John Wiley and Sons, UK, (2001)
Engg Salvendy ISBN-10: 0471502766
11 Six Sigma Project Milwaukee, WI: ASQ Quality Press.
Lowenthal,
Management: APocket . (2001), Lowenthal, J. N
Guide JN ISBN: 087389-519-3
12 McGraw-Hill, New York, (2018)
The Six Sigma Handbook. Pyzdek, T. ISBN-13: 978-0071372336

14. SOFTWARE/LEARNING WEBSITES

a) https://nptel.ac.in/courses/112107143/8
b) https://www.youtube.com/watch?v=SRV27U2LBf0
c) https://vvww.youtube.com/watch?v=I20z5cyr9qs
d) https://vvww.ifm.eng.cam.ac.uk/research/dstools/quality-function-deployment
e) https://www.pinterest.com/pin/34269647143168477/
f) https://vvvvw.simplileam.com/reasons-to-do-six-sigma-certification-article
g) https://www.youtube.com/watch?v=ZUZKtzhivQo
h) https://www.youtube.com/watch?v=4zrbfsAdEw0
i) https://wwvv.youtube.com/watch?v=ENS b6B sM_ci 8
j) http://vvww.safetycare.com/en/shop/ergonomics-2/

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