Quality Control

Quality

Definition:-

➢Degree of excellence which a thing possesses

➢The feature that make something what it is
➢Crosby defines as conformance to the requirements
➢Juran- fitness for use.
➢Customer satisfaction
➢Quality is a degree, to which , a specified product is
preferred over competing products of equivalent grade,
based on consumer’s preference
➢Ishkawa-usefulness of projects and services with
satisfaction of customer
 External Supplier

Vendor
Supplier

Customer Purchase

Supplier
Production
Customer
Supplier

Customer Quality
Control
Supplier

Customer
Sales
Supplier

Customer
Buyer
/ User
External Customer
Quality Control:

Factors affecting the Quality

1. Machines
2. Material used
3. Men
4. Manufacturing process
5. Dimensional variation in product(assembly).
6. Inspection stage

Quality specification:-

Specification is definition of design, the design remains a concept

in the mind of designer, until he defines it through verbal
description, sample drawing etc.
Quality specification:-
1. Standard Standard bodies formulates the specification for
various types of product. Bureau of Indian
Standard(BIS)

2. Consumer – When BIS standard is not suitable or

Available for a particular customer needs ;
customer provides the specification to suits his
particular needs

3. Company- When company manufactures the products on

its own specification due to varied constrained
and consumer accept them.

4. Contract- specification decided by contract reached

between manufacturer and customer
Quality Control

An effective system for integrating the quality development,

quality maintenance, and quality improvement efforts of various
departments in organization with common goal.

OBJECTIVE:-
Reduce manufacturing cost
Improved Income of company
Customer satisfaction.
Achieve interchangeability

Integration of quality effects

1 Produce optimum quality

Quality mindness.
 Quality of Quality of
Quality of design Conformance Performance
•It concerned with •It concerned with how •It concerned with how
tightness of the well the manufactured well manufactured
specifications for product confirms to the product gives its
manufacturing of the Q.O.D. performance
product •Once design established •It depends upon QOD &
•Good Q.O.D. must it is Necessary to obtain QOC
ensure consistent high QOC QOD+QOC=QOP
performance, overload •Factors controlling QOC
capacity, efficiency etc. Instruments used,
Also consider all types calibration of instruments
of failure like stress, inspection types,
wear ,shocks etc frequency of inspection,
environmental condition
etc
Reliability

•Design of any component should be such that, the product should

have long service life with few failures
•If product design is more complex failure chances are more

•It is ability of a product to perform a required function under stated

condition for stated period of time without failure
Mathematically,
RT=e-T =Failure rate T=unit time

•Goals:-
1. Fixing mean time between failure(MTBF)
=Reciprocal of  called as MTBF
2. Fixing mean life to 1st failure.
3. Fixing wear out time for product.
Elements of Reliability

1. Numerical values of probability

It helps to make reliability a number, a probability can be expressed as
standards
2. Intended function
It means product must perform a certain function, whenever asked.
i.e. Satisfactory performance
Iron used at various types of fabric at various temperature
3. Life
Product is capable of working satisfactory throughout the expected time.
4. Environment conditions

Factors considered while designing Reliability

1. Simplicity of product.
2. Provide more safety margin.
3. Provide stand by component in event failure of primary component
4. Safe operation.
5. Parts protected from temp, vibration, etc
6. Product should be easily maintainable & serviceable
Cost of Quality
The cost of carrying out the company’s function i.e. meeting the quality needs of
the customers are known as Cost of Quality.
It includes
➢Market research cost( discovering needs of customer)
➢Product R & D cost of creating product concept
➢Design cost
Total Cost
➢Cost of manufacturing planning
➢Cost of inspection
➢Cost of quality assurance Minimum Failure &
➢Cost of field services cost appraisal
cost

Cost of product in r/s

As per American Society of
Quality Control

•Cost of prevention Preventive Cost

•Cost of appraisal
•Cost of failure(internal & external) High Optimum Cost Quality of product
Cost of Prevention Cost of Appraisal Cost of Failure
•It consist of cost •It consist of costs •It is cost of all product &
associated with associated with services, which fails to
preventing product of measuring, evaluating or comply with their
defective part auditing products, specifications & drawings.
•It include components and •Classified as
Cost of quality purchased material 1) Cost of internal failure
planning •It includes Defective products,
Cost of quality control Receiving parts components & materials
Cost of quality inspection
engineering, technical In process part 2) Cost of External failure
and supervisory inspection Cost because of shipment
Cost of investigation, Finished parts of defective to the
analysis and correction inspection consumer
Setup for inspection
Quality audit
review of test &
inspection data
Value of Quality

Company rewarded by earning higher share of market, few

complaints from customer and firmer prices.

➢It is defined as direct or indirect returns gained by the company

due to mission of quality control

It is combination of
1. Value inherent in design
2. Value inherent in the conformance to design
Optimum Quality of Design It is Balance between Cost & Value of
Quality

D Cost of Quality
Cost

Value of
B
Quality

1 2 3 Quality of Design
Inspection

Inspection is act of checking of material, product or components of products at

various stages of manufacturing
Includes
1. Interpretation of specifications
2. Measurement of product
3. Comparison of 1 & 2 whether the product confirm to prescribed standard
or not.
Objective
1. Receiving inspection- Incoming raw material parts
2. In process inspection- To inspect of raw material undergoes from one m/c to
another
3. Finished good inspection- To inspect the finished products to find out the
defects & its sources. It required for supplying good products to customer.
4. Consumer satisfaction & company goodwill- for preventing the delivery of
defective products to customer
5. To facilitate the manufacturer of interchangeable parts.
6. Decision on scrap- some defective product may be acceptable after minor
repair.
 Inspection
Stages Types

1) Off line Inspection

It is performed away from the manufacturing process

Advantages
1. High tech equipments can be used
2. No problem of dust/dirt etc
3. No errors of temperature variation
4. Better analysis is possible
Disadvantages
1. Material handling cost is high
2. Chances of breaking are more
3. Direct feedback are not to be given to workers
2) In line Inspection

A) Incoming inspection(Receiving inspection)

Inspection of incoming raw materials, components, sub
assemblies and purchased parts to ensure they are according to
specification

B) In process Inspection
It is inspection of raw materials as it undergoes processing from
one operation to another operation
i. First piece inspection
ii. Floor inspection
iii. Operator inspection
iv. Last piece inspection
v. Centralized inspection
i. First piece inspection
Carried out on 1st item made after the machine set-up
If the work piece confirm to prescribed standard, operator
allowed to carry out further production

Adva. Wastage is min.

Fault in setting up of M/C or process identified
& corrected
Disadva Production can not started till 1st price
inspected
Men & M/C remains idle for inspection
ii. Floor inspection
Item is checked at machine or at floor
Inspector checks samples from M/C to M/C and work
performed by various operator.
Adv. -Suitable when product manufactured are
heavy
-handling of material reduced
-It saves time
-Line layout of machinery need not to be
disturbed
-Defects may quickly identified n corrected
Disadv. -Environmental effect may takes place
Vibration, Dust, Poor lighting, temp etc
-Pressure from worker to accept the work
-Precision instrument can not perform on floor
-Cost of inspection is high
iii. Operator inspection
The operator him self carries out inspection during
manufacturing
iv. Last piece inspection
It is carried out on the last item manufactured in the lot
Helps to indentify faults in the equipment/set-up before
beginning the next lot.
v. Centralized inspection
Inspection carried out in separated room fully equipped with
all measuring instruments n inspection device
Used when high accuracy & precision required.
Used when inspection device cannot brought on floor
vi. Final Inspection
Carried out after the final manufacturing stage
Used because prevent defective products being sent to
customer
Inspection Planning

Inspection Planning is a part of planning for quality

It include:-

1. Selection & design of inspection

2. Planning of activities at each inspection station
3. Selection of inspection path
4. Decision on requirement of tool, gauges & test devices
5. Gauge maintenance & maintaining test equipment.
6. Decision on scrap.
 Inspection Quality Control
1) It is part of Quality control 1) It involves inspection at various stages,
but more inspection does not mean QC

2)It is act of checking material, parts 2)It is an effective system for integrating
component or product at various stage of quality development, Q maintenance &Q
manufacturing & sorting out the improvement effort of various
defectives from good parts departments in an organization to
enable the production to be carried out
at the most economical level & to
achieve consumer satisfaction.

3)It is uses precision measuring 3)It is uses tools such as Statistical Control
instruments & gauges like vernier, Tool Charts, acceptance sampling, quality
maker’s microscope, Profile projector audits

4)It is concerned with quality of past 4) It is concerned with quality of future

production production
5) Inspectors are responsible for the 5)Everybody working in an organization is
inspection activity responsible for quality of products
produced
Quality assurance

It deals with the assurance of quality, reliability & services

in the product through scientific techniques
It is nothing but, the evaluation of the company activities of the quality,
reporting the evaluation to those, who are concerned with it and necessary
information of the quality and subsequent action taken
3 main steps of QA
1. Design stage:-
Q o Design meets to the max customer needs
2. Manufacturing stage :-
Manufacturing specification conform to the design specification
3. Field observation:-
Reliability & performance of product the actual field

Total Q. A= Q. o. D. + Q. o. Conformance+ Q. o. Performance

Advantage :- Consumer satisfaction

Improved productivity
Less scrap Fewer defects
Fewer complaints from customer
TOTAL QUALITY CONTROL

It is effective system of integrating quality development, quality

improvement, and quality maintenance efforts of all department in an organization, so as to
enable production & services at most economic levels, which allows full customer
satisfaction.

6 phases
1. Comprehension

2. Commitment

3. Competence

4. Communication

5. Correction

6. continuance
Quality is a Journey,
not a Destination