Having worked for a major OEM automaker with GREAT quality ratings, I found their method of QC to be extraordinarily simple - many GO-NOGO gages.

Having worked for a rolling element bearing maker, they too had many in process checks (IE: 100% clearance measurements, 100% noise tests, etc all done with sophisticated electronics using proprietary algorithms). Size control checks were done with air gages, all calibrated against the same standard regularly - process control was deadly accurate, again with simple gages religiously checked/maintained.

We make prototype camshafts. Our lobes are all 100% computer inspected for profile and finish prior to being shipped. The shape of the acceleration profile (2nd derivative of lift curve) tells us if and where an error may exist. WHen you make parts on a onesy twoesy basis, PPM's are irrelevant. 1 part in a million is probably 100% of our production.

The inspection process you'r being asked to quantify/describe is going to be hard to get your arms around. I'd first create a hypothetical widget. Once you know what the critical features are, you can then set up an inspection method and the equipment thereof. A that point, the project can be defined as can the level of inspection, and all the other stuff you're being asked to provide.

For example, in camshafts, you can have a overall lift variation allowance of 0.003". Yet, on a degree by deg lift variation, you have to hold deviation under 0.0001"/deg. Yet length issues can vary by 0.005 in some areas and 0.030 in others - all tolearance of the SAME feature, a lobe.

BIG difference in the inspection method and equipment and time needed to do the certification.

Whether or not you can do adaptive controls of the process is a function of the type of equipment being used to make something and how much freedom the operator has to "tune it". Contrary to what your prof says, there are still industries operating with analog control systems that involve hard tooling and trained operators - not everything is CNC'd nor "tuneable".

EDIT: one more important issue: you can NOT inspect quality into a part. You have to develop an attitude that you will BUILD quality into it from the get go.

Demand perfection and provide your staff with the tools to provide it and you find that your staff will strive to deliver it and take pride in doing so. You will make money by NOT making scrap....

When you lower your expectations (and your level of quality), your staff will not fail to disappoint you....