Quality+management

Inspection and Quality control QualityQuality is Fitness for the purpose Quality is Conformance to requirements Quality is Value perceived by the customer Quality is customer satisfaction achieved through product features and freedom from deficiencies

Historical development of quality management • • • •

Stage I – Inspection Stage II – Quality Control Stage III – Quality Assurance Stage IV – Total Quality Management

The Achievement of Quality •

Quality of design (Functional + Safety + Maintainability + Reliability + Esteem) Requirements should be considered 3. Customer acceptance of the product and its price 4. Quality of design and manufacturing lead time

• Quality of Conformance • Quality standards Material Specification Dimensional Specification Performance Specification Environmental Specification

Quality control Three basic aspect of quality control • Acceptance function • Preventive function • Assurance function

Benefits of Inspection & QC • Ensure adequate maintenance of quality • To satisfy customer and to meet competition • Assurance of fitness in assembly • Reduction of defective work and scrap • Prevent labor and machine time for rework • Control on incentive plan

Quality Control Vs Inspection Quality Control 1. Aims to produce better quality product 2. Determine the causes of variation & suggest methods to minimize it 3. Determine what, when and how much to inspect

Inspection 1. One of the tool used to achieve it 2. Determine the acceptability

3. Actually conduct the examination

Inspection planning 1. What to inspect (Specification)? 2. When to inspect (Stages of inspection)? • Inspection, sampling or cent percent • Prior to a long Run 1. First off inspection 2. Pilot piece inspection • Production is coming off line- patrolling • Before transfer to other section • Critical operation inspection

• Prior to costlier operation • Prior to operation which conceal the defect of previous operation • Before an operation which is likely to endanger costly tooling • First few pieces produced after replacement of form tools • The completed assemblies • Prior to the shipment of the goods to the customer • Job received back from customer as defective • Non reworkable pieces -Salvage inspection

3. Where to inspect (Place of inspection)? • Inspection of Incoming materials- Vendors place & Home place • Inspection During manufacturing • Inspection of finished product • Inspection of jigs & fixtures • Inspection of Tools • Inspection of gauges

4. How to Inspect (Inspection devices)? • Measuring instruments • Limit gauges • Multiply gauges • Automatic gauges • Laboratory testing equipments • Non destructive testing -visual, liquid penetration, magnetic flaw detector, ultrasonic, radiography etc

5. How much to inspect (Sampling or Cent percent Inspection)? • Cost of inspection Vs cost of failure • Nature of inspection • Lot size • Manufacturing process • Stage of inspection • Functional importance of the item • Stage of development • Result of sampling inspection • Vendors quality rating • Natural tolerance Vs design tolerance • Industry wise practice

How to exercise control over quality • Preparation of quality std and specification • Exercising control over inputs – raw material, tools, jigs and fixtures • Exercising control during manufacturing • Inspection prior to shipment of goods • Periodical analysis of inspection reports • Method study to reduce defectives • Suggestion scheme to improve quality • Training • Creating quality consciousness in the organization

Quality control of purchased material 1. Defining the right quality 2. Selecting suppliers for quality i. By reputation ii. By vendor plant survey iii. By experience 3. Ensuring supplier understand requirements 4. Monitoring suppliers qualityPlace and extend of inspection 5. Defect identification and defect prevention 6. Vendor performance evaluation

Quality control of work done at the home plant 1. Preparation of process sheet of component 2. Drawing for each stage of operation 3. Inspection by the workmen 4. Periodical inspection during manufacturing 5. Inspection during assembly 6. Final inspection