Quality
Control
JACQUES S. OSMEÑA
Bachelor of Science in Industrial Engineering
COTE – Industrial Engineering Department
It may refer to the quality of the process (i.e., men, material, and
machines) and even that of management. Where the quality
manufactured product referred as or defined as “Quality of product
as the degree in which it fulfills the requirement of the customer. It
is not absolute but it judged or realized by comparing it with some
standards”.
Quality
Crosby defined as “Quality is conformance to requirement or
specifications”.
Juran defined as “Quality is fitness for use”.
“The Quality of a product or service is the fitness of that product or
service for meeting or exceeding its intended use as required by
the customer.”
Quality
(9 M’s) Factors Affecting Quality
Market Money Management
We could see many new This should be rewarded Because of the increased
products to satisfy by improved productivity. complex structure of
customer wants. it is the This is possible by business organization, the
role of companies to minimizing quality costs quality related
identify needs and then associated with the responsibilities lie with
meet it. maintenance and persons at different levels
improvements of quality in the organization.
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level.
(9 M’s) Factors Affecting Quality
Men Motivation Materials
The rapid growth in It is a responsibility to give Selection of proper
technical knowledge leads motivation to each materials to meet the
to development of human individuals to achieve desired tolerance limit is
resource with different quality. also an important
specialization. consideration.
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(9 M’s) Factors Affecting Quality
Machines and Modern Information Mounting Product
Mechanization Methods Requirement
We need to use advanced The modern information Product diversification to
machines and mechanize methods help in storing meet customers taste
various operations. and retrieving needed leads to complexity in
data for manufacturing, design, manufacturing and
marketing and servicing. quality standards.
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The process through which the standards are established and met
with standards is called control. This process consists of observing
our activity performance, comparing the performance with some
standard and then taking action if the observed performance is
significantly too different from the standards.
Control
The control process involves a universal sequence of steps as follows:
1. Choose the control object
2. Choose a unit of measure
3. Set the standard value
4. Choose a sensing device which can measure
5. Measure actual performance
6. Interpret the difference between actual and standard
7. Taking action.
Control
Need for Controlling Quality
In the absence of quality, the following will result:
1. No yardstick for comparing the quality of goods/services.
2. Difficulty in maintaining consistency in quality.
3. Dissatisfied customers due to increased maintenance and operating costs of
products/services.
4. Increased rework cost while manufacturing products/providing services.
5. Reduced life time of the products/services.
6. Reduced flexibility with respect to usage of standard spare parts.
7. Hence, controlling quality is an essential activity.
Inspection is an important tool to achieve quality concept. It is necessary to
assure confidence to manufacturer and aims satisfaction to customer.
Inspection Is an indispensable tool of modern manufacturing process.
Inspection only measures the degree of conformance to a standard in the
case of variables. In the case of attributes inspection merely separates the
nonconforming from the conforming. Inspection does not show why the
nonconforming units are being produced.
Inspection
Inspection is the most common method of attaining standardization,
uniformity and quality of workmanship.
The inspection and test unit is responsible for appraising the quality of
incoming raw materials and components as well as the quality of the
manufactured product or service. It checks the components at various
stages with reference to certain predetermined factors and detecting and
sorting out the faulty or defective items.
Inspection
Types of Inspection: Floor Inspection
In this system, the inspection is performed at the place of production. It
suggests the checking of materials in process at the machine or in the
production time by patrolling inspectors and does not disrupt the line layout.
These inspectors move from machine to machine and from one to the other
work centers. Inspectors have to be highly skilled.
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Types of Inspection: Centralized Inspection
Inspection is carried in a central place with all testing equipment, sensitive
equipment is housed in air-conditioned area. Samples are brought to the
inspection floor for checking. Centralized inspection may locate in one or more
places in the manufacturing industry.
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Types of Inspection: Combined Inspection
Combination of two methods whatever may be the method of inspection,
whether floor or central. The main objective is to locate and prevent defect
which may not repeat itself in subsequent operation to see whether any
corrective measure is required and finally to maintain quality economically.
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Types of Inspection: Functional Inspection
This system only checks for the main function, the product is expected to
perform. Thus an electrical motor can be checked for the specified speed and
load characteristics. It does not reveal the variation of individual parts but can
assure combined satisfactory performance of all parts put together. Both
manufacturers and purchasers can do this, if large number of articles are
needed at regular intervals. This is also called assembly inspection.
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Types of Inspection:
First Piece or First Off Inspection
First piece of the shift or lot is inspected. This is particularly used where
automatic machines are employed. Any discrepancy from the operator as
machine tool can be checked to see that the product is within in control limits.
Excepting for need for precautions for tool we are check and disturbance in
machine set up, this yields good result if the operator is careful.
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Types of Inspection: Pilot Piece Inspection
This is done immediately after new design or product is developed.
Manufacturer of product is done either on regular shop floor if production is
not disturbed. If production is affected to a large extent, the product is
manufactured in a pilot plant. This is suitable for mass production and
products involving large number of components such as automobiles aero
planes etc., and modification are design or manufacturing process is done until
17 satisfactory performance is assured or established.
Types of Inspection: Final Inspection
This is also similar to functional or assembly inspection. This inspection is
done only after completion of work. This is widely employed in process
industries where there is not possible such as, electroplating or anodizing
products. This is done in conjunction with incoming material inspection.
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Methods of Inspection
100% Inspection Sampling Inspection
This type will involve careful In this method randomly
inspection in detail of quality at selected samples are inspected.
each strategic point or stage of Samples taken from different
manufacture where the test is patches of products are
involved is non-destructive and representatives. If the sample
every piece is separately proves defective, the entire
inspected. It requires more concerned is to be rejected or
number of inspectors and hence recovered. Sampling inspection
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it is a costly method. is cheaper and quicker.
Methods of Inspection
Following are the disadvantages of inspection:
1. Inspection adds to the cost of the product but not for its value.
2. It is partially subjective, often the inspector has to judge whether a
products passes or not.
3. Fatigue and Monotony may affect any inspection judgment..
4. Inspection merely separates good and bad items. It is no way to
prevent the production of bad items.
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Drawbacks of Inspection
100% Inspection Sampling Inspection
This type will involve careful In this method randomly
inspection in detail of quality at selected samples are inspected.
each strategic point or stage of Samples taken from different
manufacture where the test is patches of products are
involved is non-destructive and representatives. If the sample
every piece is separately proves defective, the entire
inspected. It requires more concerned is to be rejected or
number of inspectors and hence recovered. Sampling inspection
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it is a costly method. is cheaper and quicker.
Quality Control (QC) may be defined as a system that is used to maintain a desired
level of quality in a product or service. It is a systematic control of various factors
that affect the quality of the product. It depends on materials, tools, machines, type
of labor, working conditions etc.
QC is a broad term, it involves inspection at particular stage but mere inspection
does not mean QC. Quality control aims at prevention of defects at the source, relies
on effective feedback system and corrective action procedure. Quality control uses
inspection as a valuable tool.
Quality Control
According to Juran “Quality control is the regulatory process through which we
measure actual quality performance, compare it with standards, and act on the
difference”.
ANSI/ASQC standard (1978) quality control is defined as “The operational
techniques and the activities which sustain a quality of product or service that will
satisfy given needs; also the use of such techniques and activities”.
Quality Control
Types of Quality Control
Off-line Quality Control Statistical Process Control Acceptance Sampling
Its procedure deal with involves comparing the Plans
measures to select and output of a process or a A plan that determines the
choose controllable service with a standard number of items to sample
product and process and taking remedial and the acceptance
parameters . actions in case of a criteria of the lot, based on
discrepancy between the meeting certain stipulated
two. conditions .
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ISHIKAWA DIAGRAM
Seven Tools of Quality
Also known as “Cause-and-
Effect Diagram” or “Fishbone
Diagram”
Identifies many possible causes
for an effect or problem and
sorts ideas into useful
categories.
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FLOWCHART
Seven Tools of Quality
A diagram that describes steps
in the process.
It can help investigators in
identifying possible points in a
process where problems occur.
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CONTROL CHARTS
Seven Tools of Quality
A graph used to study how a
process changes over time.
Comparing current data to
historical control limits leads to
conclusions about whether the
process variation is consistent
(in control) or is unpredictable
(out of control, affected by
27 special causes of variation).
CHECK SHEETS
Seven Tools of Quality
A tool for recording and
organizing data to identify a
problem.
A structured, prepared form for
collecting and analyzing data.
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HISTOGRAM
Seven Tools of Quality
The most commonly used graph
for showing frequency
distributions, or how often each
value in a set of data occurs.
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PARETO CHART
Seven Tools of Quality
A bar graph that shows which factors
are more significant.
Often referred as 80-20 rules, Pareto
concept states that approximately 80
percent of the problems come from
20 percent of the items.
A diagram that arranges categories
30 from highest to lowest frequency.
SCATTER DIAGRAM
Seven Tools of Quality
Graphs pairs of numerical data, one
variable on each axis, to look for a
relationship
This means a correlation may point
the cause of problem.
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Causes of Variation in Quality
Chance Causes Assignable Causes
The chance causes are those Variation due to these causes
causes which are inherit in can be controlled before the
manufacturing process by virtue defective items are produced.
of operational and constructional Any one assignable cause can
features of the equipment result in a large amount of
involved in a manufacturing variation in process.
process.
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The concept of quality circles is based on the participating style of management. It assumes
that productivity will improve through an uplift of morale and motivations which are in turn
achieved through consultation and discussion in informal groups. It is typically an informal
group of people that consists of operators, supervisors, managers and so on who get
together to improve ways to make the product or deliver the service.
Quality circles pursue two types of problems, those concerned with the personal well being
of the worker and those concerned with the well being of company. Quality Circles affect
individual characteristics, relations with other, and workers and attributes.
Quality Circles
Total Quality Management (TQM), quality is not a technical function, but a systemic process
extending throughout all phases of the business, e.g., marketing, design, development,
engineering, purchasing, production/operations.
As per Feigebaum, “Total Quality Management is an effective system of integrating the
quality development, quality maintenance and quality improvement efforts of various
groups in an organization so as to enable marketing, engineering, production and service at
the most economical levels which allow for full customer satisfaction”.
Total Quality Management
TQM
increase productivity
With a higher quality
product and lower
price, competitive
position in the
marketplace will be quality
products
enhanced. and services
to customer
35 lower costs
Skill Development
Use the production or service facilities you used in the past
activity and get the information for the following questions:
1. Quality Control Technique adopted for raw materials.
2. Maintenance of Quality in the process of manufacture
3. Method of quality control technique (inspection or sampling
technique)
4. Quality Control tools used
5. Total Quality Management approach for continual
improvement if quality
6. Quality standard certification
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Thanks!
Any questions?
You can find me at:
▰ Jacques Osmeña
▰
[email protected]37
