What is Inspection?

Definition- "Measuring, examining, testing and gauging one or more characteristics of a product or
service and comparing the results with specified requirements to determine whether conformity is
achieved for each characteristic." - 2859

• Inspection can be performed at several places in production: from acceptance of the raw materials
and parts from the suppliers to the shipping of the products to the customers.

Inspected products can be the components used for production, Inventory, or finished
goods.

For manufacturing systems are in continuous operation and subject to breakdown. Inspection can
be an appropriate maintenance strategy
Role of Inspection in Manufacturing:

"Intellectuals solve problems. geniuses prevent them"

-Albelt EitL%teiJl

Inspection: Watchdog manufacturing process,

Final

Pro
duct
Feedback
Inspection is performed m an manufacturing Industry to prevent the defects from passing further down the line
and 10 make the product as per the required specifications.

Inspection is done to minimize the rework and scrap costs manufacturing,

Rework - The transformation of products not fulfilling the present specification into products that
do, e,g, correcting of defective, failed, 01' non-conforming items, during or after inspection.

Scrap - Waste that either has no economic value 01' only the value of its basic material content
recoverable through recycling.

Scrap and rework are an incredible drain on company resources.

Scrap and rework costs are incurred due to many reasons. for example:

When the wrong parts or raw materials are ordered.

Machine malfunction or human error o When designs are not properly executed on
the manufacturing line.
 When engineering changes aren't effectively communicated o Product damaged in

transit,

Functions of Inspection:
Inspection is normally carried out:

I To find out physical imperfections (such as surface defects and internal defects etc.),

2, To check the quantity (such as numbers. volume, and weight etc.),

3, To check the physical dimensions (such as length. width, height, and thickness etc.).

4 To check the nominal size (usually done for the bulk raw materials).

5, To check the physical appearance (such as brightness, dullness, rusting, weathering, colour, solid. liquid
etc,)

6, To check the chemical composition.

7 To check physical. mechanical, and electrical properties like density or specific gravity. dimensional
product shape, temperature, tensile strength, microstructure, fracture analysis etc.

8 To check many other properties which are specific to certain products such as coating thickness in
case of coated products, refractoriness and apparent porosity etc.
Basic Issues of Inspection:

The purpose of inspection is to provide information on the degree to which items conform to a
standard

At what points 111 the process Inspection should occur?

How much to inspect and how often?

Whether to inspect attributes (counts) or variables

(measures)?
 Whether to Inspect In a centralized or on-site location?

1. Where to inspect?
• Inspection always adds to the cost of the product; therefore it is impoltant to restrict
Inspection eff01ts to the points i!here they can give the more advantage.
Sta es of Inspection and Testing ,

Incoming materials Semi-finished Finished product

Ill-process material
product inspection
Inspection and testing inspection and testing Inspection and testing
and testing

Incoming materials Inspection and Testing:

Incoming Inspection is called as Raw Material Inspection and it is done for the purchase order

This procedure covers inspecting purchased supplier material i.e raw material, purchased pads, subcontracted goods
etc.

ll. Ill-process .11dterial Inspection and Testing:

It is performed when the product is transferred from one process to the next.

Its purpose is to prevent defected goods from entering the next process and producing further damage.

Ill, Semi-finished Product Inspection und Testing:

It is performed processed parts, and assemblies, and it does not Include the completely finished goods,

IJI Finished Product Inspection and Testing:

It is the inspection pelf01ned the final stage of manufacturing process.

 In this test, whether the complete goods meet the requirements as a product or not is determined in order to prevent the

loss in customer confidence, various problems, and damages 111 advance.

Example- (Automobile Production Line):

Accepted Raw Witenal (Afiel Inspection): primer/Üodtrcoat

& Stamp og, Steel, plication ginti

spec 00
body

roccss

Weldin Sh0
Chassis Fgbfiotioo CarBody

final Assembling
 Inspietion ind Shipping
CgrBodyAs$nbling
 to inspect?
2. How much

• The amount of inspection can range from no inspection to inspection of each item
many times.

• Low-cost, high volume items such as paper clips and pencils often require little
inspection because

The cost associated With passing defective items IS quite low

The process that produces these items are usually highly reliable, so that defects
are rare,

• High-cost, low volume items that have large cost associated with passing defective
items often require more Intensive inspection such as airplanes and spaceships.

• The majority of quality control applications ranges between these two extremes.
 • The amount of inspection needed is governed by the cost of inspection and the
expected cost of passing defective items.

Optimal Amount of Inspection

• The complete setup and execution of inspection activities Increase total production cost.

• Total inspection cost IS the sum of the fixed cost and the variable cost, in which the variable COSI is
related 10 the quantity Inspected per day.

• The fixed cost Includes the setup cost and salaried workers of the Inspection area

• For calculating Ille optimal amount of inspection the variable cost is taken into consideration.
 to inspect?

Total Cost = Cost of inspection + Cost of passing

defectives

3. Whether Attributes (Counts) or Variables (Measures)?

• Basically, there are two types of data to collect as part of an inspection procedure:

a) Attribute (Discrete) Data:

• Quality characteristic for which a numerical value is not specified.

• Il is a qualitative data that can be counted for recording and analysis.

 • For example: taste, paint quality, quality of output, no, of defects, no. of defectives, no, of
scrap items. etc,

b) Variable (Continuous) Data:

It is a measurement information of the product,

For example: length. volume. time, etc,

They are both important information, but variable data is generally more useful
as it is more precise and contains more information,

Attribute Data Variable Data

Attribute data focuses on numbers or go/no-go Variable data focuses on measurements on a

Information. continuous scale.
 to inspect?
Attribute data Simply classifies the output as Variable data tells that how bad each defective
defective or not defective. product is: 10% faulty. 20% faulty. and so on

Variable data can tell us many things that attribute

Attribute data is Simpler to gather, so ifs a good
data can’t
choice [five are looking at a binary condition. for
• With variable data trends are seen allowing for
example: allowing for corrective action to be taken long
before the product reaches the reject level.
• The product works or it doesn't Bork. The
parts fit the slot or not.
• Students pass the test, or they fail.
Example: Example:

Temperature

Sin

Broken or I

4. Whether in a centralized or on-site location?

 Based on the timing and place of the inspection procedure In relation to the manufacturing
process, two alternative situations are possible:
I. Offline or Centralized Inspecti011 Il. On-site Inspection

Off-line or Centralized Inspection:

Off-line or centralized inspection is performed away from the manufacturing process,

and there is generally a time delay between processing and Inspection. Generally,

111 these Inspection activities.

More specialized testing equipment are used.

s/ More favourable testing environment is needed,

For example: Medical tests, analyzing food samples, testing metals for hardness, running
viscosity tests on lubricants etc,

Continued...
On-site Inspection:
 to inspect?
The alternative to off-line inspection is on-line inspection, in which the procedure is
performed when parts are made,

In this case, quicker decisions can be made and extraneous factors (e.g. surface
scratches) can be avoided

For example.' Inspecting the hull of a ship for cracks, construction site inspection.

Centralized or on-site location?

Effects on cost and level of disruption are major issues in selecting centralized vs on-site
inspection,
What is Quality?
Quality has no specific meaning unless related 10 a specific function and/or object.

The definition of "quality" has changed over time, and their various interpretations are given
below:

The totality of features and characteristics of a product or services that bear on its ability to satisfy
stated or Implied needs of the customers (ISO).

Quality of a product or service is the fitness of that product or service for meeting its intended use
required by the customer (JOSEPH JURAN),

Quality is conformance to specifications (EDWARD DEMING).

Quality is conformance to requirements (PHILIP CROSBY).

Quality is the customer sap, it is (FEIGENBAUM).

" The common element of the above definitions is that the quality) of a product or service refers to
the perception of the degree to which the product or service meets the customer's expectations,

Continued„.

+ Perceived quality is governed by the gap between customers' expectations and their
perceptions of the product or service.

Customers' Gap Customers'

Gap perceptions perceptions
ofthe ofthe
product or product ot
Customers'
perceptions
Customers' ofthe product Clßtomets'
expectations or expectations
for the for the Customers'
product or product or expectations
service service for the
product or
service

Expectations > Pelteptions Expectations = Perceptions Expectations < Peneptions

 Petvei\ed quality is poor Perceilcd quality is acceptable Perceived quality is good
Dimensions of Product Quality:

As prescribed by Garvin, the eight dimensions of quality are:

l. Performance (will the product do the Intended job?)

2 Conformance (does the product meets the specifications?)

3, Reliability (how often the product falls?)

4. Durability (how long the product lasts?)

5. Serviceability (how easy is to repair the product?)

6. Aesthetics (what does the product looks, feels, sounds, smells, or tastes?)

7. Features (what does the product do? For example extra features added to basic features)

8. Perceived (quality (what is the reputation of a company?)

What is Quality Control?

Definition: Inspection, analysis and action applied to a portion of the product 111 a
manufacturing operation to estimate overall quality of the product and determine what, if
any, changes must be made to achieve or maintain the required level of quality
Proper Planning of

RightDeslgn
It involves inspection and testing units
and determining if they are within the
specifications for the final product. Quality control ofa productProper equppnenl can
be as a system which ensures:
Proper Inspeclion
The purpose of the testing IS to
determine any needs for corrective
actions In the manufacturing process Corrective action
Cost of Quality:
• Money spent beyond expected production costs (labour, materials, equipment) to ensure
that the product the customer receives IS a quality (defect free) product

• It quantifies the total cost of quality-related efforts and deficiencies in manufacturing a

product
 It include downtime, repair costs,
It include the cost arises from efforts
rework, scrap, and employee
to prevent or detect defects.
turnover
Four Cost Categories Related to Ouality
 External Failure Cost

Cost of good quality Cost of poor quality

Cost of achieving good quality is the Investment Cost of poor quality (COPQ) are costs that would
made by the company 111 proactive quality disappear if systems, processes, and products were
management practices and planning,
perfect,

Prevention Cost

o Cost of planning and executing a project so it is error free or within an acceptable error range,

•9 Example: Cost of training and performing acceptance sampling of raw materials, SQC, Six Sigma, and other
techniques.

Appraisal Cost o Cost of evaluating process and their outputs to

ensure quality.
 Example: Cost of detecting defects in the final product ie. outgoing inspection of products before being shipped to
customers

Internal Failure Cost o Cost incurred to correct an identified defect before the customer

receives the product.

•3 Example: Cost of scrap and rework of defective products- This includes the extra paper work, delays,
rescheduling required, etc.

an External Fault? Cost of Cost that relates to all errors not detected and corrected before delivery

to the customer

+ Example: Cost of Warranty Claims- This also includes the loss of goodwill on the part of customers,

Activities Associated with Different Cost Categories:

Cost of rectifying error over the product development stages:
 The cost of rectifying errors increases more rapidly the longer they remain uncorrected in
the development and launch process.

The sooner, the better: the sooner we find the

error, the cheaper the cost will be.

Criticality of failure of a part at different stages:

I. Failure at supplier's site (bad)

Il Failure at manufacturer's site (worse) Stages in development and launch

pmcess

Ill Failure at customers' site (worst)

 Pilot prodilclion

Impact of Quality Management on Costs:

Total cost of quality is ultimately reduced by Investing money up front in quality design
and development

Increasing the effort spent on preventing errors occurring in the first place brings a more
than equivalent reduction in other cost categories.

Example:

If we design the product

right first time, build it right
first time • we save all the
 •

costs of redesign, rework, resetting,

repair, warranty work etc,

Impact of Higher Quality on Value:

What is value?

Value is "the amount buyers are willing to pay for what a firm provides them. Value is
generally measured by the total revenue of the company"

A firm's value goes beyond its financial performance and it includes social impact and
strategic importance to the regional and national economy
Less Waste

higher quality on value:

 Higher Quality

Summary:

Inspection is performed to assess the conformity with design specification and

to Improve the product quality and reliability

Basic issues related to the inspection manufacturing has been discussed

Quality control Involves Inspection and testing of units and helps in determine the needs
of corrective action during manufacturing.

A proper inspection and quality control system ultimately reduces the total cost by
minimizing the scrap and rework losses.