1、DEPARTMENT OF DEFENSEHANDBOOKCOMPANION DOCUMENTTO MIL-STD-1916This handbook is for guidance only. Do not cite this document as a requirement.AMSC N/A AREA QCICNOT MEASUREMENTSENSITIVEMIL-HDBK-191610 February 1999Provided by IHSNot for ResaleNo reproduction or networking permitted without license fro
2、m IHS-,-,-MIL-HDBK-1916iiFOREWORD1. This handbook is approved for use by all Departments and Agencies of the Department ofDefense. This document provides guidance on the use of MIL-STD-1916 to defense contractorsand other commercial organizations supplying goods and services to the U.S. Government.
3、Themost significant difference between MIL-STD-1916 and previous product acceptance MilitaryStandards is its emphasis on process-oriented improvement efforts. MIL-STD-1916 promotes theuse of alternate methods of acceptance to sampling, and specifically endorses the implementationand use of a statist
4、ical process control (SPC) program. In compliance with DoD procurementquality strategy, MIL-STD-1916 emphasizes prevention. Furthermore,MIL-STD-1916 allows freedom on the part of suppliers to develop, plan, and implement theirown quality system in so far as it is prevention-oriented and founded on t
5、he principles ofcontinuous improvement of process and product quality. The standard also provides a series ofzero-based sampling plans that can be used for product acceptance.2. This handbook is for guidance only. This handbook cannot be cited as a requirement ; if it is, thecontractor does not have
6、 to comply.3. Continuous quality improvement is a basic concept currently embedded in the DoD/DefenseIndustries Quality Excellence Program. The DoD has stated that Military and FederalSpecifications that prescribe fixed levels of nonconformances, such as Acceptable Quality Levels( AQLs) and Lot Tole
7、rance Percent Defectives ( LTPDs ), inhibit quality improvements andeffective competition based on excellence, and should be eliminated. While Military and FederalSpecifications may continue to utilize sampling techniques, DoD procurement activities have beeninstructed not to include prescribed AQLs
8、, LTPDs, or other requirements for allowable levels ofnonconformances.4. The discontinued use of specifications incorporating AQLs and LTPDs, and contractualreference to standards based on them, left a serious void in the procurement quality assessment. The avoidance of language in procurement docum
9、ents and standards which could be construed asallowing any nonconformances, led to the adoption of plans with acceptance numbers (c) of zero.In response to this mandate to not specify fixed levels of nonconformances in procurement,MIL-STD-1916 was developed by a committee comprised of volunteer memb
10、ers from education,government, and industry. This standard can be used in lieu of MIL-STD-105, MIL-STD-414,MIL-STD-1235, ANSI/ASQC Z1.4, and ANSI/ASQC Z1.9.5. Beneficial comments (recommendations, additions, deletions) and any pertinent data which maybe useful in improving this document should be ad
11、dressed to: Commander, U.S. Army ArmamentResearch, Development and Engineering Center, ATTN: AMSTA-AR-EDE-S, Picatinny Arsenal,NJ 07806-5000, by using the Standardization Document Improvement Proposal (DD Form 1426)appearing at the end of this document or by letter.Provided by IHSNot for ResaleNo re
12、production or networking permitted without license from IHS-,-,-MIL-HDBK-1916iiiCONTENTSPARAGRAPH . PAGEFOREWORD iiSection 1: SCOPE 11.1 Purpose . 11.2 Applicability 1Section 2: APPLICABLE DOCUMENTS . 12.1 General . 12.2 Government documents . 12.2.1 Specifications, standards, and handbooks . 12.3 N
13、on-Government publications . 22.4 Order of precedence 2Section 3: DEFINITIONS, ACRONYMS and SYMBOLS 23.1 Definitions . 23.2 Acronyms used in this handbook 63.3 Symbols 7PART A: PREFERRED METHODOLGY of ACCEPTANCE 8Section 4: QUALITY SYSTEM . 84.1 Prevention vs. detection . 84.2 Prevention-based quali
14、ty system 84.3 Providing process focus of quality system 84.3.1 Design of experiments . 94.3.2 Tools for design 94.3.2.1 Quality Function Deployment 94.3.2.2 Failure Mode and Effects Analysis . 94.3.3 State of operator control . 10Section 5: STATISTICAL PROCESS CONTROL . 115.1 General . 115.1.1 Why
15、SPC? . 115.1.2 Service and administrat ive SPC . 115.1.3 Customer requirements 115.2 Planning for SPC . 125.2.1 Approach 125.2.2 Preliminary planning 125.2.2.1 Senior management . 12Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-1916iv5.2.2
16、.2 Quality system . 125.2.2.3 Steering committee 125.2.2.4 SPC facilitator . 125.2.2.5 SPC policy 1 35.2.2.6 Goals 135.2.2.7 Milestones . 135.2.2.8 SPC plan . 135.2.2.9 SPC verification 135.2.3 Training . 145.3 Process knowledge 155.3.1 Flow diagramming . 155.3.2 Additional tools and techniques to g
17、ain knowledge of the process 155.3.3 Characte rizing variation . 155.3.4 Determining optimum process settings . 165.4 What to measure . 165.4.1 Key characteristics to control 165.4.2 Process variables to control product characteristics 165.5 Normality 175.5.1 When and why normality is important 175.
18、5.2 Tests for normality 175.5.3 Transformations/Curve-fitting 185.6 Control charting 185.6.1 The basic control chart and its use . 185.6.2 Types of control charts 185.6.2.1 Variable charts 185.6.2.2 Attributes charts 195.6.3 Rational subg roups 205.6.4 Rationale for subgroup size . 225.6.5 Rationale
19、 for sampling frequency . 225.6.6 SPC for short run production . 235.6.6.1 Control charts for short run production - variables data . 235.6.6.2 Control charts for short run production - attribu te data 245.6.7 Control chart auditing 245.7 Assess stability, capability, and performance 245.7.1 Stabili
20、ty . 245.7.1.1 Introduction 245.7.1.2 Criteria (interpretation) 245.7.1.3 Verification . 255.7.2 Capability 255.7.2.1 Introduction 255.7.2.2 Process capability index = C p =(USL-LSL)/(6 sigma) . 265.7.2.3 Capability of non-normal distributions . 265.7.2.4 Capability for one-sided specifications . 26
21、5.7.2.5 Verification . 26Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-1916v5.7.3 Performance 275.7.3.1 Introduction 275.7.3.2 Index 275.7.3.3 Performance for non-normal data distributions . 275.7.3.4 Verification . 275.7.3.5 Economic posi
22、tioning of process . 285.7.3.6 Continuous improvement prioritization 285.7.4 Other measures 285.8 Gaging and measurement . 285.9 Final acceptance by SP C 295.9.1 Requirements for acceptance . 295.9.2 Actions for acceptance by SPC 295.9.3 Customer report generation . 295.9.4 Submission to the custome
23、r . 30Section 6: ACCEPTANCE by OTHER METHODS (NEITHER SPC NORMIL-STD-1916 SAMPLING TABLES) . 346.1 General . 346.1.1 Poka-Yoke or mistake proofing . 346.1.2 Calibrated fixtures as a media of inspection 346.1.3 100% automated inspection . 35PART B: SAMPLING INSPECTION TABLES . 36Section 7: GENERAL .
24、367.1 Why c= 0? 367.2 Background of tables . 367.3 Risk equivalents/OC curves . 36Section 8: PLANNING for SAMPLING . 378.1 Classification of characteristics 378.2 How to select verification levels 378.3 Sampling of group characteristics vs individual characteristics . 378.3.1 Table II attribute plan
25、s a nd Table III variable plans 378.3.2 Table IV continuous plans . 378.4 Limitations of use 37Section 9: Use of the SAMPLING TABLES . 389.1 Assumptions/prerequisites for each table 389.1.1 Table II - Attributes sampling plans . 389.1.1.1 Random sample . 3 89.1.1.2 Stratification 389.1.2 Table III -
26、 Variables sampling plans . 389.1.2.1 Random sample . 38Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-1916vi9.1.2.2 Stratification 389.1.2.3 Normal distribution . 389.1.3 Table IV - Continuous sampling plans . 389.2 Switching rules - logic
27、 and background 399.3 Disposition of lot/batch where customer acceptance is withheld . 439.4 Examples of use of tables 449.5 Variables sampling two-sided specification limits with different VLs 449.6 Auditing of MIL-STD-1916 sampling decisions and actions . 45Section 10: NOTES 4510.1 Intended use 45
28、10.2 References . 4510.3 Subject term (keyword listing) . 45FIGURE1 Submission for systemic approval before contract award 312 Submission for systemic approval after contract award 323 Submission fo r individual approval at any time during contract 334 Switching rules for lot or batch sampling . 405
29、 Switching rules for continuous sampling 41D-1 to D- 78 OC, AFI, AOQ Curves 56 - 107TABLEA Sample size rules for variable contr ol charts . 19B Sample size rules for attribute control charts 20C Example of multiple sources of variation 21D Values for CASES 1-7 42D-I to D- XXVI AoZ, variables, contin
30、uous plans 57 - 107D-XXVII Summary of attributes pla ns 108D-XXVIII Summary of variables plans . 109D-XXIX Summary of continuous plans 110APPENDIXA SPC software considerations . 46B Selective process improvement tools . 48C References . 51D OC curves . 55E Background an d rationale of tables . 111F
31、Examples of use of MIL-STD-1916 sampling tables . 112G An example of an SPC Audit checklist 119CONCLUDING MATERIAL 120Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-19161Section 1 : SCOPE1.1 Purpose . The purpose of this handbook is to:a. P
32、rovide guidance on using MIL-STD-1916 to improve industrial practices throughstatistical process control and other continuous improvement techniques. b. Furnish an understanding of how the sampling inspection plans work and how they can bereplaced by alternate acceptance methods.1.2 Applicability .
33、This handbook is for guidance only. This handbook cannot be cited as arequirement. If it is, the contractor does not have to comply. Please note that in MIL-STD-1916and this Handbook the following word pairs are used synonymously:a. contractor, supplierb. subcontractor, vendorc. customer, government
34、Section 2 : APPLICABLE DOCUMENTS2.1 General . The documents listed below are not necessarily all of the documents referencedherein, but are the ones that are needed in order to fully understand the information provided bythis handbook.2.2 Government documents .2.2.1 Specifications, standards, and ha
35、ndbooks . The following specifications, standards, andhandbooks form a part of this document to the extent specified herein. Unless otherwisespecified, the issues of these documents are those listed in the latest issue of the Department ofDefense Index of Specifications and Standards ( DoDISS) and s
36、upplement thereto. STANDARDSDEPARTMENT OF DEFENSEMIL-STD-1916 - DoD PREFERRED METHODS FOR ACCEPTANCE OFPRODUCT(Unless otherwise indicated, copies of the above specifications, standards, and handbooks areavailable from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D,Philadelp
37、hia, PA 19111-5094.)Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-191622.3 Non-Government publications . The following document(s) form a part of this document tothe extent specified herein. Unless otherwise specified, the issues of the do
38、cuments which areDoD adopted are those listed in the latest DoDISS, and supplement thereto. INTERNATIONAL ORGANIZATION FOR STANDARDIZATIONISO 9000 SERIES - QUALITY MANAGEMENT AND QUALITY ASSURANCE STANDARDS(Copies of international standards, catalogs, and handbooks (ISO and IEC), as well as allforei
39、gn standards from ISO member body countries (DIN, JISC, BSI, AFNOR, etc.) are availablein the U.S. from ANSI, 11 West 42 nd Street, New York, NY 10036 . )AMERICAN NATIONAL STANDARDS INSTITUTE/AMERICAN S OCIETY FORQUALITYANSI/ASQC 9000 SERIES - QUALITY MANAGEMENT AND QUALITY ASSURANCE STANDARDS(Appli
40、cation for copies should be addressed to Quality Press, 611 East Wisconsin Avenue, P.O.Box 3005, Milwaukee, WI 53201-3005)2.4 Order of precedence . In the event of a conflict between the text of this document and thereferences cited herein, the text of this document takes precedence. Nothing in this
41、 document,however, supersedes applicable laws and regulations unless a specific exemption has beenobtained.Section 3 : DEFINITIONS, ACRONYMS and SYMBOLS3.1 Definitions . The following definitions supplement those found in MIL-STD-1916:a. Alpha risk ( ) . This is also known as the producers risk. Whe
42、n referring to lotacceptance sampling, it is the probability that an acceptable lot will be rejected. When applied tocontrol charts, the alpha risk is the probability that an out-of-control signal will be observed whenthe process is actually in control.b. ANOVA (Analysis of Variance) . A technique t
43、hat subdivides the total variation of a setof data into meaningful component parts associated with specific sources of variation for thepurpose of testing some hypothesis on the parameters of the model or estimating variancecomponents. The technique, in conjunction with the F ratio, is used to provi
44、de a test ofsignificance for the effects of these sources of variation and/or to obtain estimates of the variancesattributable to these sources. The basic assumptions are that the effects due to all the sources ofvariation are additive and that the experimental errors are independently and normally
45、distributedwith zero mean and have equal variances throughout all subdivisions of data.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-19163c. Benchmarking . A continuous, systematic process for evaluating the products, services,and work pro
46、cesses of organizations that are recognized as representing best practices for thepurpose of organizational improvement.d. Beta risk ( ) . This is also known as the consumers risk. When referring to lotacceptance sampling, it is the probability that a lot of rejectable quality will be accepted. When
47、applied to control charts, the beta risk is the probability that an out-ofcontrol condition will notbe observed when it actually exists. e. Bonus Tolerance (also known as “Increase in Positional Tolerance”) . Where the actualsize of a feature is at maximum material condition (MMC), the geometric tol
48、erance is zero. Wherethe actual size of the feature has departed from MMC, an increase in the geometric tolerance isallowed (bonus tolerance) equal to the amount of such departure. The total permissible variationis maximum at least material condition (LMC).Bonus tolerancing is applied on an MMC, LMC, or regardless of feature size” (RFS) basis. Thebonus tolerance, datum, and symbols are contained within feature control frames. This tolerance isin addition to the feature tolerance and permits the feature location and form to vary from true(theoretical
