Preface to the Second Edition |
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xv | |
Preface to the First Edition |
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xvii | |
Authors |
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xxi | |
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1 Introduction to Quality |
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1 | (48) |
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1.1 An Historical Overview |
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1 | (8) |
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1.1.1 A Note about "Quality Engineering" |
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7 | (2) |
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9 | (2) |
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1.2.1 Product Quality vs. Service Quality |
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11 | (1) |
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1.3 The Total Quality System |
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11 | (2) |
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1.4 Total Quality Management |
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13 | (2) |
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15 | (1) |
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1.6 Quality, Productivity, and Competitive Position |
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16 | (1) |
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17 | (22) |
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1.7.1 Categories of Quality Costs |
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18 | (1) |
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18 | (2) |
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20 | (1) |
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1.7.1.3 Internal Failure Cost |
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20 | (1) |
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1.7.1.4 External Failure Cost |
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21 | (1) |
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1.7.2 Steps in Making a Quality Cost Study |
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21 | (5) |
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1.7.3 Projects Arising from a Quality Cost Study |
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26 | (1) |
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1.7.4 Quality Cost Scoreboard |
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27 | (2) |
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1.7.5 Quality Costs Not Included in the TQC |
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29 | (2) |
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1.7.6 Relationship among Quality Cost Categories |
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31 | (1) |
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1.7.7 Summary of Quality Costs |
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32 | (1) |
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1.7.8 A Case Study in Quality Costs |
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32 | (7) |
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39 | (1) |
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39 | (10) |
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39 | (4) |
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43 | (3) |
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46 | (3) |
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49 | (94) |
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2.1 Variability in Populations |
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49 | (1) |
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50 | (2) |
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2.2.1 The Population and a Sample |
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50 | (1) |
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51 | (1) |
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2.3 Quality vs. Variability |
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52 | (1) |
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2.4 Empirical Methods for Describing Populations |
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53 | (14) |
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2.4.1 The Frequency Distribution |
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53 | (1) |
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53 | (1) |
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2.4.1.2 The Cumulative Frequency Distribution |
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54 | (5) |
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2.4.2 Numerical Methods for Describing Populations |
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59 | (2) |
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2.4.2.1 Calculating the Average and Standard Deviation |
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61 | (1) |
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2.4.3 Other Graphical Methods |
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61 | (1) |
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2.4.3.1 Stem-and-Leaf Diagram |
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61 | (2) |
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2.4.3.2 Box-and-Whisker Plot |
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63 | (1) |
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2.4.4 Other Numerical Measures |
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64 | (1) |
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2.4.4.1 Measures of Location |
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64 | (1) |
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2.4.4.2 Measures of Dispersion |
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65 | (1) |
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2.4.5 Exercise in Empirical Methods |
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65 | (2) |
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2.5 Mathematical Models for Describing Populations |
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67 | (46) |
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2.5.1.1 Definition of Probability |
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68 | (1) |
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2.5.1.2 Computing the Probability of an Event |
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69 | (3) |
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2.5.1.3 Theorems on Probability |
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72 | (8) |
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2.5.1.4 Counting the Sample Points in a Sample Space |
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80 | (5) |
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2.5.2 Exercise in Probability |
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85 | (2) |
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2.5.3 Probability Distributions |
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87 | (1) |
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87 | (2) |
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2.5.3.2 Probability Mass Function |
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89 | (2) |
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2.5.3.3 Probability Density Function |
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91 | (1) |
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2.5.3.4 The Cumulative Distribution Function |
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92 | (1) |
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2.5.3.5 The Mean and Variance of a Distribution |
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93 | (3) |
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2.5.4 Some Important Probability Distributions |
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96 | (1) |
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2.5.4.1 The Binomial Distribution |
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96 | (3) |
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2.5.4.2 The Poisson Distribution |
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99 | (2) |
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2.5.4.3 The Normal Distribution |
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101 | (8) |
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2.5.4.4 Distribution of the Sample Average X |
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109 | (1) |
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2.5.4.5 The Central Limit Theorem |
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110 | (1) |
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2.5.5 Exercise in Probability Distributions |
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111 | (2) |
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2.6 Inference of Population Quality from a Sample |
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113 | (24) |
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114 | (1) |
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2.6.2 Confidence Intervals |
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115 | (1) |
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2.6.2.1 CI for the μ of a Normal Population When σ Is Known |
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115 | (1) |
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2.6.2.2 Interpretation of CI |
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116 | (1) |
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2.6.2.3 CI for μ When σ Is Not Known |
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117 | (1) |
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2.6.2.4 CI for σ2 of a Normal Population |
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118 | (2) |
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120 | (1) |
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2.6.3.1 Test Concerning the Mean σ of a Normal Population When σ Is Known |
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121 | (2) |
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2.6.3.2 Why Place the Claim Made about a Parameter in H1? |
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123 | (1) |
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2.6.3.3 The Three Possible Alternate Hypotheses |
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124 | (1) |
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2.6.3.4 Test Concerning the Mean σ of a Normal Population When σ Is Not Known |
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125 | (2) |
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2.6.3.5 Test for Difference of Two Means When σs Are Known |
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127 | (2) |
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2.6.4 Tests for Normality |
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129 | (1) |
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2.6.4.1 Use of the Normal Probability Plot |
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129 | (1) |
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2.6.4.2 Normal Probability Plot on the Computer |
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130 | (3) |
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2.6.4.3 A Goodness-of-Fit Test |
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133 | (1) |
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134 | (1) |
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2.6.6 Exercise in Inference Methods |
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135 | (1) |
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2.6.6.1 Confidence Intervals |
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135 | (1) |
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2.6.6.2 Hypothesis Testing |
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136 | (1) |
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2.6.6.3 Goodness-of-Fit Test |
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137 | (1) |
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137 | (6) |
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142 | (1) |
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143 | (74) |
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143 | (1) |
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3.1.1 The Product Creation Cycle |
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143 | (1) |
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144 | (22) |
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3.2.1 Finding Customer Needs |
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145 | (1) |
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146 | (4) |
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3.2.2 Quality Function Deployment |
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150 | (2) |
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3.2.2.1 Customer Requirements and Design Features |
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152 | (1) |
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3.2.2.2 Prioritizing Design Features |
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153 | (1) |
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3.2.2.3 Choosing a Competitor as Benchmark |
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154 | (1) |
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154 | (1) |
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3.2.3 Reliability Fundamentals |
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155 | (1) |
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3.2.3.1 Definition of Reliability |
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156 | (1) |
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156 | (2) |
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3.2.3.3 The Bathtub Curve |
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158 | (3) |
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3.2.3.4 Distribution of Product Life |
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161 | (1) |
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3.2.3.5 The Exponential Distribution |
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161 | (1) |
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3.2.3.6 Mean Time to Failure |
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162 | (3) |
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3.2.3.7 Reliability Engineering |
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165 | (1) |
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166 | (31) |
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166 | (1) |
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3.3.2 Design of Experiments |
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167 | (1) |
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3.3.2.1 22 Factorial Design |
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168 | (2) |
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170 | (1) |
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3.3.2.3 Experimental Results |
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171 | (1) |
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3.3.2.4 Calculating the Factor Effects |
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172 | (1) |
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173 | (1) |
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3.3.2.6 Interaction Effects |
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174 | (1) |
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3.3.2.7 A Shortcut for Calculating Effects |
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175 | (1) |
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3.3.2.8 Determining the Significance of Effects |
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175 | (3) |
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178 | (4) |
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3.3.2.10 Interpretation of the Results |
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182 | (1) |
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183 | (1) |
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184 | (1) |
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185 | (1) |
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3.3.3.1 Traditional Approaches |
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185 | (1) |
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3.3.3.2 Tolerancing According to Dr. Taguchi |
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186 | (1) |
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3.3.3.3 Assembly Tolerances |
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187 | (1) |
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188 | (3) |
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3.3.3.5 Natural Tolerance Limits |
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191 | (1) |
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3.3.4 Failure Mode and Effects Analysis |
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191 | (4) |
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3.3.5 Concurrent Engineering |
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195 | (1) |
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3.3.5.1 Design for Manufacturability/Assembly |
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196 | (1) |
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197 | (1) |
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197 | (12) |
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3.4.1 The Process Flow Chart |
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198 | (2) |
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3.4.2 Process Parameter Selection: Experiments |
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200 | (4) |
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204 | (1) |
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205 | (1) |
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3.4.5 Process Control Plan |
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205 | (1) |
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3.4.6 Other Process Plans |
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205 | (1) |
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3.4.6.1 Process Instructions |
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205 | (2) |
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3.4.6.2 Packaging Standards |
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207 | (1) |
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3.4.6.3 Preliminary Process Capabilities |
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207 | (1) |
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3.4.6.4 Product and Process Validation |
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207 | (1) |
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3.4.6.5 Process Capability Results |
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208 | (1) |
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3.4.6.6 Measurement System Analysis |
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208 | (1) |
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3.4.6.7 Product/Process Approval |
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208 | (1) |
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3.4.6.8 Feedback, Assessment, and Corrective Action |
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208 | (1) |
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209 | (8) |
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209 | (3) |
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212 | (2) |
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214 | (3) |
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4 Quality in Production---Process Control I |
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217 | (80) |
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217 | (1) |
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218 | (3) |
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4.2.1 A Typical Control Chart |
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219 | (2) |
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221 | (1) |
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4.3 Measurement Control Charts |
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221 | (24) |
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222 | (6) |
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4.3.2 A Few Notes about the X- and R-Charts |
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228 | (1) |
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4.3.2.1 The Many Uses of the Charts |
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228 | (1) |
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4.3.2.2 Selecting the Variable for Charting |
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229 | (1) |
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4.3.2.3 Preparing Instruments |
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230 | (1) |
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4.3.2.4 Preparing Check Sheets |
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230 | (1) |
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4.3.2.5 False Alarm in the X-Chart |
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231 | (1) |
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4.3.2.6 Determining Sample Size |
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231 | (1) |
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4.3.2.7 Why 3-Sigma Limits? |
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232 | (1) |
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4.3.2.8 Frequency of Sampling |
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233 | (1) |
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4.3.2.9 Rational Subgrouping |
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233 | (2) |
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4.3.2.10 When the Sample Size Changes for X- and R-Charts |
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235 | (1) |
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4.3.2.11 Improving the Sensitivity of the X-Chart |
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236 | (1) |
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4.3.2.12 Increasing the Sample Size |
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236 | (2) |
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4.3.2.13 Use of Warning Limits |
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238 | (1) |
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238 | (2) |
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4.3.2.15 Patterns in Control Charts |
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240 | (1) |
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4.3.2.16 Control vs. Capability |
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240 | (2) |
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242 | (3) |
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4.4 Attribute Control Charts |
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245 | (17) |
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245 | (3) |
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248 | (3) |
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4.4.3 Some Special Attribute Control Charts |
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251 | (1) |
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4.4.3.1 The P-Chart with Varying Sample Sizes |
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251 | (3) |
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254 | (1) |
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4.4.3.3 The Percent Defectives Chart (100P-Chart) |
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255 | (1) |
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255 | (3) |
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4.4.4 A Few Notes about the Attribute Control Charts |
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258 | (1) |
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4.4.4.1 Meaning of the LCL on the P- or C-Chart |
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258 | (1) |
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4.4.4.2 P-Chart for Many Characteristics |
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259 | (1) |
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259 | (1) |
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4.4.4.4 Rational Subgrouping |
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259 | (3) |
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4.5 Summary on Control Charts |
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262 | (6) |
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4.5.1 Implementing SPC on Processes |
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263 | (5) |
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268 | (7) |
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4.6.1 Capability of a Process with Measurable Output |
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268 | (1) |
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4.6.2 Capability Indices Cp and Cpk |
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269 | (5) |
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4.6.3 Capability of a Process with Attribute Output |
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274 | (1) |
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4.7 Measurement System Analysis |
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275 | (14) |
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4.7.1 Properties of Instruments |
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275 | (2) |
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4.7.2 Measurement Standards |
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277 | (2) |
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4.7.3 Evaluating an Instrument |
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279 | (1) |
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4.7.3.1 Properties of a Good Instrument |
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279 | (1) |
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4.7.3.2 Evaluation Methods |
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279 | (1) |
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280 | (3) |
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283 | (1) |
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4.7.3.5 Variability (Precision) |
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284 | (3) |
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4.7.3.6 A Quick Check of Instrument Adequacy |
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287 | (2) |
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289 | (8) |
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289 | (4) |
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293 | (3) |
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296 | (1) |
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5 Quality in Production---Process Control II |
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297 | (78) |
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298 | (6) |
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5.1.1 Limits for the X-Chart |
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298 | (3) |
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5.1.2 Limits for the R-Chart |
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301 | (1) |
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5.1.3 Limits for the P-Chart |
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302 | (1) |
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5.1.4 Limits for the C-Chart |
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303 | (1) |
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5.2 Operating Characteristics of Control Charts |
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304 | (11) |
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5.2.1 Operating Characteristics of an X-Chart |
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304 | (1) |
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5.2.1.1 Computing the OC Curve of an X-Chart |
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305 | (2) |
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5.2.2 OC Curve of an R-Chart |
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307 | (2) |
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309 | (3) |
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5.2.4 OC Curve of a P-Chart |
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312 | (1) |
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5.2.5 OC Curve of a C-Chart |
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313 | (2) |
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5.3 Measurement Control Charts for Special Situations |
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315 | (24) |
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5.3.1 X- and R-Charts When Standards for μ and/or σ are Given |
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315 | (1) |
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5.3.1.1 Case I: μ Given, σ Not Given |
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316 | (1) |
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5.3.1.2 Case II: μ and σ Given |
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316 | (3) |
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5.3.2 Control Charts for Slow Processes |
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319 | (1) |
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5.3.2.1 Control Chart for Individuals (X-Chart) |
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320 | (2) |
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5.3.2.2 Moving Average and MR Charts |
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322 | (2) |
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5.3.2.3 Notes on Moving Average and Moving Range Charts |
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324 | (2) |
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5.3.3 The Exponentially Weighted Moving Average Chart |
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326 | (5) |
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5.3.3.1 Limits for the EWMA Chart |
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331 | (2) |
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5.3.4 Control Charts for Short Runs |
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333 | (1) |
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333 | (2) |
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5.3.4.2 The Standardized DNOM Chart |
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335 | (4) |
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5.4 Topics in Process Capability |
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339 | (10) |
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340 | (1) |
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5.4.2 Comparison of Cp, Cpk, and Cpm |
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341 | (1) |
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5.4.3 Confidence Interval for Capability Indices |
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342 | (2) |
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5.4.4 Motorola's 6σ Capability |
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344 | (5) |
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5.5 Topics in the Design of Experiments |
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349 | (20) |
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5.5.1 Analysis of Variance |
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349 | (6) |
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5.5.2 The General 2k Design |
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355 | (1) |
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356 | (1) |
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5.5.4 2k Designs with Single Trial |
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357 | (2) |
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5.5.5 Fractional Factorials: One-Half Fractions |
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359 | (2) |
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5.5.5.1 Generating the One-Half Fraction |
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361 | (1) |
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5.5.5.2 Calculating the Effects |
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361 | (1) |
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5.5.6 Resolution of a Design |
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362 | (7) |
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369 | (6) |
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369 | (3) |
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372 | (1) |
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373 | (2) |
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375 | (34) |
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6.1 Managing Human Resources |
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375 | (27) |
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6.1.1 Importance of Human Resources |
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375 | (1) |
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376 | (1) |
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6.1.2.1 Organization Structures |
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376 | (2) |
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6.1.2.2 Organizational Culture |
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378 | (2) |
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380 | (1) |
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6.1.3.1 Characteristics of a Good Leader |
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380 | (1) |
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381 | (2) |
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6.1.5 Open Communications |
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383 | (2) |
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385 | (2) |
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6.1.7 Education and Training |
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387 | (1) |
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6.1.7.1 Need for Training |
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387 | (1) |
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6.1.7.2 Benefits from Training |
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388 | (1) |
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6.1.7.3 Planning for Training |
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388 | (2) |
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6.1.7.4 Training Methodology |
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390 | (1) |
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6.1.7.5 Finding Resources |
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391 | (1) |
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6.1.7.6 Evaluating Training Effectiveness |
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392 | (1) |
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392 | (1) |
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393 | (1) |
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6.1.8.2 Selecting Team Members |
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393 | (1) |
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6.1.8.3 Defining the Team Mission |
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393 | (1) |
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6.1.8.4 Taking Stock of the Team's Strength |
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394 | (1) |
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6.1.8.5 Building the Team |
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394 | (1) |
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6.1.8.6 Basic Training for Quality Teams |
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395 | (1) |
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6.1.8.7 Desirable Characteristics among Team Members |
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396 | (1) |
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397 | (1) |
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6.1.8.9 Ground Rules for Running a Team Meeting |
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397 | (1) |
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6.1.8.10 Making the Teams Work |
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398 | (1) |
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6.1.8.11 Different Types of Teams |
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399 | (1) |
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400 | (1) |
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401 | (1) |
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6.1.10 Principles of Management |
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402 | (1) |
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6.2 Strategic Planning for Quality |
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402 | (5) |
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6.2.1 History of Planning |
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402 | (2) |
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6.2.2 Making the Strategic Plan |
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404 | (1) |
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6.2.3 Strategic Plan Deployment |
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405 | (2) |
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407 | (2) |
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407 | (1) |
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408 | (1) |
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408 | (1) |
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409 | (48) |
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7.1 Importance of Quality in Supplies |
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409 | (1) |
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7.2 Establishing a Good Supplier Relationship |
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410 | (1) |
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7.2.1 Essentials of a Good Supplier Relationship |
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410 | (1) |
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7.3 Choosing and Certifying Suppliers |
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411 | (3) |
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7.3.1 Single vs. Multiple Suppliers |
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411 | (1) |
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7.3.2 Choosing a Supplier |
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412 | (1) |
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7.3.3 Certifying a Supplier |
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413 | (1) |
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7.4 Specifying the Supplies Completely |
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414 | (1) |
|
7.5 Auditing the Supplier |
|
|
415 | (1) |
|
7.6 Supply Chain Optimization |
|
|
416 | (4) |
|
7.6.1 The Trilogy of Supplier Relationship |
|
|
417 | (1) |
|
|
417 | (1) |
|
|
418 | (1) |
|
|
419 | (1) |
|
7.7 Using Statistical Sampling for Acceptance |
|
|
420 | (33) |
|
7.7.1 The Need for Sampling Inspection |
|
|
420 | (2) |
|
7.7.2 Single Sampling Plans for Attributes |
|
|
422 | (1) |
|
7.7.2.1 The Operating Characteristic Curve |
|
|
422 | (1) |
|
7.7.2.2 Calculating the OC Curve of a Single Sampling Plan |
|
|
423 | (3) |
|
|
426 | (1) |
|
7.7.2.4 Choosing a Suitable OC Curve |
|
|
426 | (2) |
|
7.7.2.5 Choosing a Single Sampling Plan |
|
|
428 | (3) |
|
7.7.3 Double Sampling Plans for Attributes |
|
|
431 | (1) |
|
|
432 | (1) |
|
7.7.3.2 The OC Curve of a DSP |
|
|
432 | (2) |
|
7.7.4 The Average Sample Number of a Sampling Plan |
|
|
434 | (2) |
|
7.7.5 MIL-STD-105E (ANSI Z1.5) |
|
|
436 | (2) |
|
7.7.5.1 Selecting a Sampling Plan from MIL-STD-105E |
|
|
438 | (9) |
|
7.7.6 Average Outgoing Quality Limit |
|
|
447 | (4) |
|
7.7.7 Some Notes about Sampling Plans |
|
|
451 | (1) |
|
7.7.7.1 What Is a Good AQL? |
|
|
451 | (1) |
|
7.7.7.2 Available Choices for AQL Values in the MIL-STD-105E |
|
|
451 | (1) |
|
7.7.7.3 A Common Misconception about Sampling Plans |
|
|
452 | (1) |
|
7.7.7.4 Sampling Plans vs. Control Charts |
|
|
452 | (1) |
|
7.7.7.5 Variable Sampling Plans |
|
|
452 | (1) |
|
|
453 | (4) |
|
|
454 | (3) |
|
8 Continuous Improvement of Quality |
|
|
457 | (52) |
|
8.1 The Need for Continuous Improvement |
|
|
457 | (1) |
|
8.2 The Problem-Solving Methodology |
|
|
458 | (6) |
|
8.2.1 Deming's PDCA Cycle |
|
|
458 | (1) |
|
8.2.2 Juran's Breakthrough Sequence |
|
|
459 | (2) |
|
8.2.3 The Generic Problem-Solving Methodology |
|
|
461 | (3) |
|
8.3 Quality Improvement Tools |
|
|
464 | (29) |
|
8.3.1 Cause-and-Effect Diagram |
|
|
465 | (1) |
|
|
466 | (1) |
|
|
467 | (4) |
|
|
471 | (1) |
|
|
472 | (2) |
|
|
474 | (2) |
|
|
476 | (3) |
|
8.3.8 Regression Analysis |
|
|
479 | (1) |
|
8.3.8.1 Simple Linear Regression |
|
|
479 | (2) |
|
|
481 | (1) |
|
8.3.8.3 Test of Significance |
|
|
482 | (5) |
|
8.3.8.4 Multiple Linear Regression |
|
|
487 | (2) |
|
8.3.8.5 Nonlinear Regression |
|
|
489 | (1) |
|
8.3.9 Correlation Analysis |
|
|
490 | (1) |
|
8.3.9.1 Significance in Correlation |
|
|
491 | (2) |
|
|
493 | (11) |
|
|
496 | (1) |
|
|
497 | (1) |
|
8.4.3 Waste and Cost Control |
|
|
498 | (1) |
|
8.4.4 Total Productive Maintenance |
|
|
499 | (1) |
|
8.4.5 Stable, Standardized Processes |
|
|
500 | (1) |
|
|
500 | (2) |
|
8.4.7 Leveling and Balancing |
|
|
502 | (2) |
|
|
504 | (1) |
|
|
504 | (5) |
|
|
504 | (2) |
|
|
506 | (1) |
|
|
507 | (2) |
|
|
509 | (66) |
|
|
509 | (1) |
|
|
510 | (8) |
|
|
511 | (1) |
|
|
512 | (1) |
|
9.2.3 Prevention Orientation |
|
|
512 | (1) |
|
9.2.4 Quality in Procurement |
|
|
513 | (1) |
|
9.2.5 Continuous Improvement |
|
|
513 | (1) |
|
9.2.6 Training, Education, Empowerment, and Teamwork |
|
|
514 | (4) |
|
|
518 | (9) |
|
|
519 | (3) |
|
|
522 | (1) |
|
9.3.3 Quality Improvement |
|
|
523 | (4) |
|
9.4 Dr. Feigenbaum's System |
|
|
527 | (3) |
|
9.5 Baldrige Award Criteria |
|
|
530 | (13) |
|
9.5.1 Criterion 1: Leadership |
|
|
533 | (1) |
|
9.5.2 Criterion 2: Strategic Planning |
|
|
534 | (1) |
|
9.5.3 Criterion 3: Customer Focus |
|
|
535 | (2) |
|
9.5.4 Criterion 4: Measurement, Analysis, and Knowledge Management |
|
|
537 | (1) |
|
9.5.5 Criterion 5: Workforce Focus |
|
|
538 | (2) |
|
9.5.6 Criterion 6: Process Management |
|
|
540 | (1) |
|
9.5.7 Criterion 7: Results |
|
|
541 | (2) |
|
9.6 ISO 9000 Quality Management Systems |
|
|
543 | (3) |
|
9.6.1 The ISO 9000 Standards |
|
|
543 | (1) |
|
9.6.2 The Eight Quality Management Principles |
|
|
544 | (1) |
|
9.6.3 Documentation in ISO 9000 |
|
|
545 | (1) |
|
9.7 ISO 9001:2008 Requirements |
|
|
546 | (15) |
|
9.7.1 Quality Management System (4) |
|
|
547 | (1) |
|
9.7.2 Management Responsibility (5) |
|
|
548 | (3) |
|
9.7.3 Resource Management (6) |
|
|
551 | (1) |
|
9.7.4 Product Realization (7) |
|
|
552 | (6) |
|
9.7.5 Measurement, Analysis, and Improvement (8) |
|
|
558 | (3) |
|
|
561 | (8) |
|
9.8.1 Six Themes of Six Sigma |
|
|
562 | (1) |
|
|
563 | (2) |
|
9.8.3 The Three Strategies |
|
|
565 | (1) |
|
9.8.4 The Two Improvement Processes |
|
|
566 | (1) |
|
9.8.5 The Five-Step Road Map |
|
|
566 | (3) |
|
9.8.6 The Organization for the Six Sigma System |
|
|
569 | (1) |
|
9.9 Summary of Quality Management Systems |
|
|
569 | (2) |
|
|
571 | (4) |
|
|
571 | (2) |
|
|
573 | (1) |
|
|
573 | (2) |
Appendix 1 |
|
575 | (12) |
Appendix 2 |
|
587 | (8) |
Index |
|
595 | |