Lesson Plan
Course Title: Manufacturing Engineering
Session Title: Analyzing Quality Control Systems
Performance Objective:
After completing this lesson, students will be able to analyze quality control system issues in a
computer integrated manufacturing process using concepts and principles of Pareto charts to
the teacher’s satisfaction.
Specific Objectives:
 Discuss the purpose of Pareto charts.
 Research and discuss terms used in the analysis of quality control issues.
 Discuss the importance of stratification in the development of Pareto charts.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the
activities may result in the elimination of any or all of the TEKS listed.
Manufacturing Engineering:

130.329(c)(8)(D)(E)
...demonstrate the use of software to control instruments;
…analyze attribute and Pareto charts.
Interdisciplinary Correlations:
Physics:

112.39(c)(2)(A)(B)(C)(D)
...know the definition of science and understand that it has limitations, as specified in
subsection (b)(2) of this section;
...know that scientific hypotheses are tentative and testable statements that must be
capable of being supported or not supported by observational evidence. Hypotheses of
durable explanatory power which have been tested over a wide variety of conditions are
incorporated into theories;
...know that scientific theories are based on natural and physical phenomena and are
capable of being tested by multiple independent researchers. Unlike hypotheses,
scientific theories are well-established and highly-reliable explanations, but may be
subject to change as new areas of science and new technologies are developed;
...distinguish between scientific hypotheses and scientific theories;
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
112.39(c)(3)(D)
...explain the impacts of the scientific contributions of a variety of historical and
contemporary scientists on scientific thought and society;
English Language Arts and Reading, English I:

110.31(b)(1)(E)
...use a dictionary, a glossary, or a thesaurus (printed or electronic) to determine or
confirm the meanings of words and phrases...

110.31(b)(12) - Reading/Media Literacy.

110.31(b)(19) - Oral and Written Conventions/Spelling.

110.31(b)(24)(A)
…listen responsively to a speaker by taking notes that summarize, synthesize, or
highlight the speaker's ideas for critical reflection and by asking questions related to the
content for clarification and elaboration;

110.31(b)(25) - Listening and Speaking/Speaking.
Occupational Correlation: (reference: O*Net – www.onetonline.org)
Industrial Engineers 17-2112.00
Similar Job Titles: Process Engineer, Engineer, Operations Engineer, Engineering Manager,
Manufacturing Specialist, Plant Engineer, Supply Chain Engineer
Tasks

Plan and establish sequence of operations to fabricate and assemble parts or products
and to promote efficient utilization.

Review production schedules, engineering specifications, orders, and related information
to obtain knowledge of manufacturing methods, procedures, and activities.

Coordinate and implement quality control objectives, activities, or procedures to resolve
production problems, maximize product reliability, or minimize costs.

Recommend methods for improving utilization of personnel, material, and utilities.

Apply statistical methods and perform mathematical calculations to determine
manufacturing processes, staff requirements, and production standards.
Soft Skills:
Judgment and Decision Making; Complex Problem Solving; Critical Thinking;
Listening
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Teacher Preparation:
Teacher should review all supporting documents such as the Analyzing Quality Control Systems
presentation and notes, Matching Terms and Definitions handout, and Pareto Chart Project
worksheet. Teachers are also encouraged to conduct their own research on lesson material;
and locate a variety of modern computerized manufacturing images to show students during the
presentation such as, common products we purchase - phones, computers, shoes, cars and
gaming equipment. Locate online videos of manufacturing processes that operate efficiently and
address defects that occur during the production process to show during the introduction of the
lesson.
References:
1. O*Net – www.onetonline.org
2. Statistical Process Control: It's a Tool, Not a Cult, (2000)
http://www.sme.org/Tertiary.aspx?id=35080&terms=statistical%20process%20control
3. The Secretary of Labor’s Report on OSHA Program Activity, P. 145-155, (2000)
http://www.osha.gov/dep/fap/Final_Report_10_7_09.pdf
4. Improve your root cause analysis, (2005)
http://www.sme.org/Tertiary.aspx?id=27486&terms=pareto%20charts
Instructional Aids:
1. Analyzing Quality Control Systems presentation and notes
2. Matching Terms and Definitions answer key
3. Pareto Chart Project worksheet answer key
4. Warm-up activity (slide 3)
Materials Needed:
1. Matching Terms and Definitions handout for each student
2. Pareto Chart Project worksheet for each student
3. Pen or pencil
4. Paper
Equipment Needed:
1. Computer
2. Internet access (optional)
3. Overhead projector
Learner Preparation:
Students must have basic computer skills.
Introduction
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Introduction (LSI Quadrant I):
SAY: Having an understanding of analyzing quality control systems will greatly contribute to
your career success.
ASK: Have you ever thought about how we expect the products we purchase to be free of
defects?
SHOW: Images of common products we purchase such as, phones, computers, shoes, cars
and gaming equipment.
SAY: The analysis of quality control system issues in manufacturing help eliminate defective
products from store inventory.
ASK: When was the last time you had to return a product to the store because it was
defective?
SHOW: Online videos of manufacturing processes that operate efficiently and address defects
that occur during the production process.
Outline
Outline (LSI Quadrant II):
Instructors can use the presentation, slides, handouts, and note pages in conjunction with the
following outline.
MI
Outline
Notes to Instructor
I. Introduction and Start of Lesson
Begin the Analyzing Quality
Control Systems
presentation.
Have students work on the
Bell Work Activity.
Slide 2
Warm-up Activity: Using the
Matching Terms and
Definitions handout, students
will pair-share and teach each
other the terms and
definitions. They may do
computer-based research to
look up the meaning.
Slide 3
II. Attribute data and Pareto charts
A.
Conforming Products
B.
Non-Conforming Products
C. Vilfredo Pareto, creator of
the Pareto chart
Discuss the differences in
conforming and nonconforming products and the
importance of data collection
to the Statistical Process
Control (SPC) process. Inform
students of the history and
creator of Pareto charts.
Slides 4-5
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III. Overview: Creating Pareto
Charts
A. Pareto chart example 1
B. Pareto chart example 2
Discuss the purpose of Pareto
charts, how to use software to
create them and all related
terms.
Slides 6-7
IV. Pareto Chart Project
A. Assign project worksheet
B. Teacher will go over
worksheet in class
Distribute and assign the
Pareto Chart worksheet to the
students. Teacher will go over
the answers in class for better
understanding.
Slides 8-9
.
Verbal
Linguistic
Logical
Mathematical
Visual
Spatial
Musical
Rhythmic
Bodily
Kinesthetic
Intrapersonal
Interpersonal
Naturalist
Existentialist
Application
Guided Practice (LSI Quadrant III):
Using Matching Terms and Definitions handout, students will pair-share and teach each other
the terms and definitions. They may do computer-based research to look up the meaning.
Independent Practice (LSI Quadrant III):
Students will complete Warm-up Activity, doing computer-based research to look up and match
the meaning of words on the handout, writing out definitions on a sheet of paper. Students will
complete the Pareto Chart Project worksheet.
Summary
Review (LSI Quadrants I and IV):
Question: How has the analysis of quality control system issues impacted the manufacturing
industry?
Answer: Quality control system analysis has contributed to the drastic reduction of
defects and quality improvement of products in many industries. Products have
fewer defects; and this increases customer satisfaction, resulting in more products being
sold.
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Question: Identify the differences between conforming and non-conforming products.
Answer: Conforming products meet customer specifications, non-conforming products
do not.
.
Question: What is necessary to become skilled in the quality control system analysis process?
Answer: Training and experience
Evaluation
Informal Assessment (LSI Quadrant III):
Oral question/answer. Students will complete definitions teacher has on the board from terms
in the Matching Terms and Definitions handout. Students will complete the Analyzing Quality
Control Systems Pareto Chart Project worksheet and will go over it in class with the teacher.
Formal Assessment (LSI Quadrant III, IV):
No formal assessment in this lesson.
Extension
Extension/Enrichment (LSI Quadrant IV):
1. Students can work in groups to find examples of manufacturing processes that have
been improved using quality control system analysis. Study them and discuss the results
within the group.
2. Students can conduct research and identify a nearby manufacturing facility that has
implemented quality control system analysis successfully, then contact the plant
manager and request a tour of the facility to find out more about how the plant prepared
for and implemented quality control system analysis. If allowed they can take photos and
conduct interviews and create a presentation for class.
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Name______________________________Date_________________Class_________
Manufacturing Engineering
Analyzing Quality Control Systems
Matching Terms and Definitions
Directions: Match the terms in Section 1 with the definitions in Section 2.
Section 1:
A. Variation
B. Random defect
C. Specific cause defect
D. Brainstorming
E. Stratification
F. Pareto Chart
G. Real time data
H. Historical data
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Section 2:
1. _____ working with a group to create a list of possible options to correct a
problem (or defect)
2. _____ in quality terms, the separation of the data into identifiable
categories to allow for easier analysis
3. _____ defects that are within our control (preventable accidents like
adding incorrect ingredients, incorrect temperature settings, inadequate
training)
4. _____ a bar graph that shows the type and quantity of defects that exist in
a process from highest to lowest
5. _____ collecting data from previous (historical) operational processes
6. _____ defects that occur during the work process
7. _____ defects that occur and the cause is outside our control (lightning,
earthquakes, war, terrorist strikes, etc.)
8. _____ collecting data in an operational process while it happens
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Manufacturing Engineering
Analyzing Quality Control Systems
Matching Terms and Definitions Answer Key
D. Brainstorming: working with a group to create a list of possible options to
correct a problem (or defect)
E. Stratification: in quality terms, the separation of the data into identifiable
categories to allow for easier analysis
C. Specific cause defect: defects that are within our control (preventable
accidents like adding incorrect ingredients, incorrect temperature settings,
inadequate training)
F. Pareto Chart: a bar graph that shows the type and quantity of defects that
exist in a process from highest to lowest
G. Historical data: collecting data from previous (historical) operational processes
A. Variation: defects that occur during the work process
B. Random defect: defects that occur and the cause is outside our control
(lightning, earthquakes, war, terrorist strikes, etc.)
G. Real time data: collecting data in an operational process while it happens
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Name______________________________Date_________________Class_________
Manufacturing Engineering
Analyzing Quality Control Systems
Pareto Chart Project
Directions: Using the information below and graphing software, create a Pareto
Chart.
Pareto Chart Project: Injection Molding Defects in Plastic Cups






incorrect color - 6
poorly formed product - 9
warped lids - 3
burned product - 12
crushed product - 7
dirt particles on product - 10
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Manufacturing Engineering
Analyzing Quality Control Systems
Pareto Chart Project Answer Key
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