MACH8006 - LAB 1

Name: GOUTHAM AYKKYATHIL____ ____ Date:

23/09/23

Prerequisite: Completion of assigned readings.

Introduction:

In this lab, students will explore variation, accuracy, precision, and repeatability. The lab
includes a number of exercises, each adding more variation to the simple process of
cutting a straw, until the final exercise, which is designed to help improve accuracy and
precision, and to reduce variation as much as possible.

Items needed:
 A variety of scissors and plastic straws

 SAE and metric rulers of various lengths and discriminations

Name and Student Number: ATHUL SUNIL KUMAR (89392260)

GOUTHAM AYKKYATHIL (8930076)
HARIKRISHNAN SURESH KUMAR VASANTHA KUMARY (8916053)
Date: 09/05/2023

EXERCISE 1 – (Week One)

Cut a plastic straw into six 25mm segments using the lined instrument provided by the
instructor. Bonus marks will be given to the group that completes this task the fastest.
Once each section is cut, line your segments up and compare the lengths of each to all the
others. Now, answer the following questions:

1. Was there a variation in the length of each segment compared to the other? If so, how much?

Yes, six segments have slight variations some pieces have larger

length than the actual needed size, some have a lesser size. The very first piece has a
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23
length of 24.5mm. second piece 25.2mm, the third piece and the fourth one has

dimensions of 25.6mm. finally, the last two segments have 24.8 and 24.9

respectively.

2. Was each segment cut accurately?

Yes, the pieces were cut accurately but when we examined each piece

separately the dimensions varied, some pieces were larger and some were

smaller than the actual 25mm, this is due to the thickness caused by the blades of the

scissor. When we cut it there may be slight changes caused by the cutting angle of

scissors and the ruler had only one mm scale so the measurement may go wrong.

The variations are from a range of 24.5mm to 25.6mm. unfortunately, we didn’t get

the accurate dimension.

 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23

3. Was each segment cut with the same precision?

Yes, segments had been cut with the same precision. The measurements have been

taken with the help of a pen, the tip of the pen is slightly larger, so it made little changes.

The cutting was made with the help of scissors, the straw had to make two cuts

Simultaneously, i.e. we need to cut two curves at a time. The ruler we used to measure the

length while transferring the length to the straw with the help of a pen may have caused the

changes. The measurements were taken in the sitting posture which also caused some errors.
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23

EXERCISE 2 – (Week two)

Pair with another group and compare your straw segments to each other.
Answer the following questions:

1. Is there any variation in the length of each of your segments compared to your partners’?

Yes, when I compared my observations with my friend, the segments have a minor
differences. Both of our pieces had exceeded the required size, while others fall short. My first
piece measures 24.5mm in length, the second one is 25.2mm, and the third and fourth pieces both
have dimensions of 25.6mm. His pieces where either above or below in measurments compared
to mine.

2. Was each segment cut accurately?

Yes, the pieces were cut with precision. However, upon closer inspection of each
individual pieces, it became evident that their dimensions differed. Some pieces exceeded the
intended 25mm size, while others fell short.this variation can be subjected to the thickness created
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23
by the scissor blade during the cutting process

3. Was each segment cut with the same precision?

Yes, the section where precisely cut using the same level of accuracy. We conducted the measurements using a
pen, and since the pen’s tip is slightly larger, it resulted minor changes.The cutting was done using scissors, and when
we had to make two cuts simultaneously, meaning we had to cut two curves at once. The ruler we taken for measuring
the length while transefering it to the straw with the pen may have introduced some variations.
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23
EXERCISE 3 – (Week Three)
As a class, discuss possible methods of improving precision and accuracy and reducing
variation. Repeating this exercise achieve better results? Why or why not?

Using a regular ruler isn’t how to perform precision cuts with minimal deviation. One way to
eliminate or reduce the deviation is to use precision equipment like gauge blocks and a dial indicator.
For this to work, a gauge block of 25mm (1 inch) is taken and used to calibrate the dial indicator.
Once this process is done, it is much easier to measure the straw pieces that we cut. To measure the
25mm pieces of straw, we keep the straw parallel to the side of the gauge block and mark the point
accurately. Once the measurement is taken, we can cut that straw into 25 mm pieces. The main reason
gauge blocks make a difference is that gauge blocks are the international standard for measurement
(like length, mass, etc.), and a ruler of mass production wouldn’t produce the same standards. This is
why a piece of 25 mm straw cut with measurements from a slip gauge is more accurate than that of a
regular ruler. Doing this experiment with the help of precision equipment has helped in producing
pieces of much more accuracy. Although using a dial gauge and slip gauges may be a more
complicated way of measurement, the accuracy and precision of these equipment stay true.
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23

Observations:

What did you observe in terms of accuracy and precision within your group and then again
with the entire class?

When the experiment was conducted within our group, we used a ruler to measure the
plastic straw, which was cut with scissors. Although this was the easiest and fastest method of
measuring the 25 mm, it wasn’t the most accurate. Four of the six pieces were flawed, either
caused by human error (parallax error), inaccurate measuring equipment (ruler), or a
combination of both. When this same experiment was conducted as a whole class, we used
precision equipment like slip gauges and a dial gauge. The use of proper equipment yielded
much better results; the number of accurate and nearly perfect pieces was the majority. This
made us realize that standardized precision equipment like slip gauges are much more accurate
and can be used in repeating the same task with utmost precision.
 MACH8006 - LAB 1
Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23

END-OF-CHAPTER QUESTIONS

1. Accuracy can only be checked by comparison with:

a. another technician or metrologist
b. a trade group
c. a higher standard
d. your boss

2. Measurement is most important to which one of the following applications?

a. Mass production of automotive parts
b. Mass production of aircraft parts
c. One-of-a-kind handicrafts
d. All manufacturing 
e. Manufacturing of parts from prepared plans

3. Measurement involves fundamental qualities. Select three qualities from the following list.
a. Roundness
b. Mass 
c. Flatness 
d. Time
e. Weight
f. Modules of elasticity
g. Length 
h. Width
i. Hardness

4. Which of the following best defines “dimensional metrology?”

a. The measurements required to manufacture products
b. Measurements found by the use of scales and other measuring instruments
c. The measurement of lines, areas, volumes, and angles 
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Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23
d. The measurement of real things, whether they be steel, wood, plastic, or any other material
e. The measurement of lines, circles, and angles

5. Select one or more of the following that are not considered to be dimensional metrology.
a. Bolt circle spacing
b. The selection of lubricants for a given bearing allowance 
c. The torque requirement for a bolted assembly
d. The tolerance required for a shaft in a bearing
e. The size limits of a mass-produced replacement part

6. The role of the inspector in industry emerged as the result of which one of the following circumstances?
a. Weapons were first mass produced.
b. Gunpowder changed the threat from weapons.
c. Foremen could not keep up with mass production rates.
d. The piece-part system was introduced. 
e. Precision measurement tools such as the micrometer were introduced to industry.

7. Of the following characteristics, select the ones that affect quality control.
a. Employee morale
b. Pride of product
c. Dimensional measurements
d. Environmental conditions 
e. Product specifications

8. For every act of dimensional metrology, one or more of the following variables may apply. Identify the single most
important variable.
a. Number of decimal places
b. Metric or customary system
c. Reliability
d. Repeatability 
e. Sensitivity

9. In this text, metrological methods or principles are emphasized rather than the measuring instruments themselves. There
are several reasons for this. Which of the following is the most important reason?
a. There is no complete agreement about the instruments.
b. Instrument manufacturers provide detailed information.
c. Principles are more interesting than methods of use.
d. Principles and methods are easily adaptable to all instruments. 

Discussion Question

10. Small errors can cost a company billions of dollars or have dire consequences.

Discuss the potential impact that small errors can have in the following industries: • Automotive • Aerospace •
Biotech/Medical

Errors in a mass-production facility or industry can have severe repercussions for a company. The more products a company
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Name: GOUTHAM AYKKYATHIL____ ____ Date:
23/09/23
manufactures within a fixed timeframe, the greater the potential for increased sales and profit margins. This is precisely why
the industry does not tolerate errors, as time equates to money, and the longer it takes to rectify a mistake, the greater the
financial losses incurred.
In the context of the automotive sector, companies like Toyota and Volkswagen are capable of assembling and rolling out a
vehicle in just 45 seconds. If a production line error occurs, it brings the entire process to a standstill, and the time needed to
identify and fix the error can range from minutes to hours. During this troubleshooting period, the company is already
hemorrhaging money, underscoring the urgency of avoiding such unforeseen errors, particularly for industry giants like
Toyota.
Similarly, the aerospace industry suffers significant setbacks when any error, regardless of its magnitude, is identified.
Unlike the automotive industry, the volume of aeronautical products produced is not as high, but the demand remains
constant. This can result in production and shipping delays, ultimately causing financial losses for the company.
In the medical field, the consequences of faulty machinery are especially dire. Devices like MRIs play a crucial role in
saving countless lives. However, any errors in these machines can lead to inaccurate readings, resulting in incorrect
diagnoses and subsequent loss of trust in the company's products. Even a minor error can translate into millions in revenue
losses for the medical industry.