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QUALITY CONTROL
NAME: SHIVANGI TALATI
ROLL NO. 110
DIV: B
CLASS: SYBMS
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INTRODUCTION
Qualitycontrol is one aspect of production planning and control. It is basically
concerned with quality production. Quality is a combination of characteristics
pertaining to the manufacture of the product and control is the quality of the
product, when the deviations in the product are more than expected. To most
people quality is variable. It is subjectively judged because it deals with the
relative goodness of a product. When a buyer boasts that his house or car is the
best, it implies high quality.
The ultimate aims of quality system should be to enable companies to share thebenefits sensibly and fairly among consumers, employees, and share holders to
raise countries standard of living and to make life better for the world as a whole.
Qualitycontrol uses statistical methods, so it is referred to as statistical quality
control (SQC). The effective implementation of qualitycontrol requires the
participation and cooperation of all the employees at every stage of the companys
activities. They are such as market research, product planning, designing,
purchasing and subcontracting production.
QUALITY requires developing, designing, producing, marketing and servicingproducts and/or service with optimum cost effectiveness and usefulness, which
customer will purchase with satisfaction. To achieve these goals all the parts of a
company top management must work together.
Introducing total quality enables the realization of benefits for everyone i.e.
Management, consumers, employees and shareholders.
Total qualitycontrol is applicable to all the functions:
Quality at work, service, information, process, divisional units, people, system and
company has to be maintained at minimum cost.In order to implement an effective QC program, an enterprise must first decide
which specific standards the product or service must meet. Then the extent of QC
actions must be determined (for example, the percentage of units to be tested
from each lot). Next, real-world data must be collected .
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MEANING OFQUALITYCONTROLQualityControl is an effective system for integrating the quality development,quality maintenance. And quality-improvement efforts of the 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.
In order to carry on these functions a separate department is created which is
called control department or simply, department of quality. The person who heads
this department carries the title of manager of qualitycontrol, manager of quality
assurance, or chief inspector. The level of qualitycontrol in an organization is
influenced by several factors namely, the quality level of significance (e.g.: food
and pharmaceutical industries), the complexity of manufacturing, and the policy of
customers. Thus, each company must establish a type of organization which best
fulfill its needs. Frequently, the qualitycontrol department is composed of a
quality engineering function, an inspection function, an a laboratory function
Qualitycontrol (QC) is a procedure or set of procedures intended to ensure that a
manufactured product or performed service adheres to a defined set of quality
criteria or meets the requirements of the client or customer. QC is similar to, but
not identical with, The phrase QualityControl is used to cover all those activities
which are directed for Defining, Controlling and Maintaining quality.
In simple words, QualityControl can be defined as:
The operational techniques and the activities that sustain the quality of a product
or service in order to satisfy given requirements. It consists of quality planning,
data collection, data analysis, and implementation.
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OBJECTIVES OFQUALITYCONTROLOBJECTIVES: qualitycontrol is designed to ensure economical production of
products of uniform quality which is acceptable to the customer.Quality controlaims at preventing the defects rather than detecting the defects
1] Establishment of quality standard:
The main objectives of qualitycontrol are the economical production of a high
quality of uniform product at the quality level the customer wants. Qualitycontrol
is basically for eliminating variations in production and in order to have uniformity
in production. So, the firm establishes quality standard to achieve its objective.
2] Locating quality deviations:
It is necessary to analyze the trend and extent of quality deviations in a
manufacturing process. Such deviations should be explained by statistical
techniques when they cannot be attributed to the element of chance. Accordingly
the deviation must be overcome with the help of the quality standard fixed by the
firm at the earlier stage.
3] Evaluation of methods and processes of production:
By evaluating the methods of processes of production, qualitycontrol helps to take
corrective measures to maintain the quality of the product during the
manufacture. And these corrective measures are indeed very important for the
firm so as they can maintain the quality and let it not fall below the standard
4] Quick sales of quality goods:
In todays world, consumers are looking for quality goods and services, so to live up
to the consumers expectation the firm needs to maintain quality. Qualitycontrol
accelerates the sale of the goods by supplying only the quality goods in the market.
Consumers also support quality goods.
5] Production of standard quality goods:
Qualitycontrol aims at manufacturing standard quality goods. Such standard
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quality goods give satisfaction to consumers and also create goodwill in the market.
As explained in the earlier point, that the quality goods makes quick sales, so while
taking this in mind the firm go for production of standard quality goods.
EVOLUTION OFQUALITYCONTROLOPERATOR QUALITYCONTROL
It was applicable during the end of nineteenth century. One worker or a group of
workers were responsible for the manufacture of the entire product and therefore
each worker controlled the quality. Since the worker or groups of workers were
responsible for that particular product, more efficiency was produced. But slowlyit became unpopular and as time progressed another method of qualitycontrol
came into existence.
FOREMAN QUALITYCONTROL
During industrial revolution, foreman or supervisor assumed the responsibility of
qualitycontrol. A production strategy designed to ensure product quality that
involves a foreman responsible for directing a group of employees performing one
set of similar tasks. So it can be said that maintaining quality of a product lied inthe hands of the foreman or supervisor of the firm. The Foreman is responsible
for supervising the inspectors at the site, and reports directly to the highest level
of supervision assigned to the site, and receives daily workload from the manager.
INSPECTION QUALITYCONTROL
Manufacturing system became complex during world war I. this time, full-time
inspectors appeared on the scene to inspect already manufactured products.
QualityControl Inspection is performed to verify quality of materials, parts and
final products. The object of this service is to independently assure that the
activities of a specified project are being performed in accordance with all
contractual specifications, codes and standards or government regulations. This is
verified through checks audits, inspections and witnessing. This service is carried
out completely independently of both the individual manufacturer or sub-
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contractor as well as the purchaser or final user. QualityControl is concerned with
actual measurement or testing or supervision of manufacturers own final product
control, either by inspection of each unit or by sample testing.
STATISTICAL QUALITYCONTROL
It is extension of inspection qualitycontrol. Statistical QualityControl provides
the statistical techniques necessary to assure and improve the quality of products.
Most of the Statistical QualityControl techniques used now have been developed
during the last century. One of the most commonly used statistical tools; Control
Charts was introduced by Dr. Walter Shewart in 1924. The end of World War II
saw increased interest in quality; primarily among the industries in Japan.
Inspectors were aided by special qualitycontrol tools like control charts. So it can
be said that in this evolution of qualitycontrol, the responsibility of the inspector
increases and also the quality of the product also increases at the same rate.
TOTAL QUALITYCONTROL
When step 4 was found to add inspection cost, firms began to develop a specific-
decision-making and operating framework for the product quality which was
effective enough to take suitable action on the qualitycontrol findings, to obtain
better quality and lower costs. System for optimizing production based on ideasdeveloped by Japanese industries from the 1950s on. The system, which blends
Western and Eastern ideas, began with the concept of quality circles, in which
groups of 10-20 workers were given responsibility for the quality of the products
they produced. It gradually evolved into various techniques involving both workers
and managers to maximize productivity and quality, including close monitoring of
staff and excellent customer service. The concept of Kaizen, the notion that
improvement must involve all members of a company, is central to TQC (Total
QualityControl).
ADVANTAGES OFQUALITYCONTROL
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The importance of qualitycontrol is, now, accepted at a global level. It is an
essential pre-condition for promoting exports. Qualitycontrol is important as it
gives benefits to producers, consumers and the society at large. Consumers are
now extremely quality conscious and they support quality products. They even
insist for superior quality goods for their safety and protection. This suggests the
importance of qualitycontrol. Even the survival of a manufacturing unit depends on
its ability to supply high quality goods to consumers. It gets capacity to compete
with rival producers through effective qualitycontrol. The advantages of quality
control to consumers and manufacturers are:
1] LOWER COSTS:
Improvement in the designs of products and process to enable production at lower
costs. Since the cost is low, it is both beneficial to manufacturer and consumer.
First, when the manufacturer will produce goods and incur low cost, then he will sell
to consumers also at comparatively low cost. So, at the end of the day, both the
parties enjoy the benefit.
2] UNIFORMITY:
Improvement in the quality level and uniformity of the finished goods and incoming
materials. If there is uniformity in the finished goods, it would be advantageous to
both manufacturers and consumers. And from the point of view from the firm, its
obligatory to maintain standard or homogeneity in their product, so as to show
consistency.
3] RELATIONSHIP:
When there is uniformity in the finished goods and also high quality level, then the
bond between the manufacturer and consumers has to be strengthened. In thisscenario, both the parties enjoy the benefits they receive, and so the relationship
improves between firm and their loyal customers.
4] ENHANCING TECHNOLOGY:
Improvement in technical knowledge and engineering data and manufacturing
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design. When all the above points go in right path, then we see enhancement in
technology. And when the technology improves, it will again promote the firm first
and later to the consumers. So, this point is again common to both in terms of
advantage.
5] REDUCTION:
If the quality is improved with the enhanced technology, and if we see reduction in
rejections, scrap, re-work, and inspection costs, it wouldnt be surprising. Once the
firm sets it standard and work on it efficiently, then there could be reduction in
re-doing the work again and other costs.
6] EFFECTIVE COMPETITION:
Sales promotion and ability to face market competition effectively is another
advantage to the manufacturer. If all the firm produces quality goods, then they
can compete effectively. That competition will not only be beneficial to
manufacturers alone, but the consumers will be a part of it. Because at the end of
the day, their competition is for the consumers only.
7] PROMOTION:
Export promotion is possible through systematic qualitycontrol as consumers,
particularly from the developed and rich countries prefer quality goods. So the
firm would be getting extra profit because they can sell or they can export at a
rate higher than they sell in domestic market. So, they are expanding their
business and as well as they are making a good profit margin from foreigners.
STEPS IN QUALITY CONTROL
Inspection is indispensable to qualitycontrol. Precisely, inspection should be of
least amount to furnish the controlrequired. Inspection should be carefully
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selected and fully linked. An inspector must remain fully acquainted with his duties
possessing keen insight for inspection jobs. He must be carefully instructed about
his responsibilities pertaining to the end produce. The principal steps in quality
control are as noted below:
1] Devising control over raw materials:
The quality of the finished product is determined mostly by the quality of raw
materials. It calls for close connection between the Raw Material Purchase
Department of the company and the vendors. As and when necessary, a resident
inspector may be deputed by the qualitycontroldepartment in the vendors place
to see that only goods in accordance with specifications are supplied. It is
advisable to inspect again the raw materials before putting them to actual use.
2] Fixing standards and specifications:
In order to make any scheme of qualitycontrol successful, It is essential to
predetermine standards and specifications. The practice should be to provide
quality instructions in the form of drawings, showing shapes, dimensions and
specifications describing color, strength, thickness, chemical composition and
similar other characteristics.
3] Exercising control over production operations:
In order to execute efficient practices, the technical expert of the Quality
control department must investigate, from time to time, the operating methods.
When such an investigation is carried out, it helps to eliminate all possible
variables.
4] Locating inspection points:
When the points at which defects occur are wrongly located or located with delay,
it hinders qualitycontrol. Therefore, there should first be the inspection of the
raw materials at the vendors places, then at the companys plant, then at the
various points during the process of production and finally at the time of packing.
The defects are likely to occur at these points. The finished goods can be cleared
after obtaining O.K. or All Correct from the qualitycontrol department.
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5] Maintaining quality of equipments:
The final quality of the products is conditioned by the quality of the equipments
and other devices used. Therefore, the qualitycontrol department is responsible
for testing the equipment used in inspection such as gauges, which measure
dimensions, electronic devices, magnetic devices, industrial radio graphical
instruments and so on.
6] Maintaining records:
The qualitycontrol department is responsible for maintaining all records relating
to quality inspection and control and the number rejected. On the part of the firm,
this is essential because a time may arrive where they will have to take a decision
on the basis on these reports of records.
QUALITY CONTROL CLASSIFICATIONQuality is a relative term. It is generally stated with reference to the end us of a
product. A product is said to be a good quality if it works well in a particular
situation for which it is meant. Quality may be classified as per the following.
1] Quality of design:
Before the product is produced, quality of design is determined. This is the level o
quality which the engineer desired the product to possess. It is desirable to get
quality level approved by marketing and operations departments. Quality of design
is stated in terms of the tolerable variations.
2] Quality of conformance:
It means producing a product to meet the specifications. When a product conforms
to specification, the product is considered to be a quality product e.g., two
machines are to produce an item with nominal size 60mm and tolerance +- 0.1mm.
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Machine 1 produces a rage of +- 0.06mm and machine 2 produces a range of +-
0.03mm, thus it can be said that machine 2 has a higher quality of conformance.
3] Quality of performance:
It refers to the ability of the product to perform its function most economically.
Quality of performance has three components:
[a] availability [b] reliability and [c] maintainability.
[a] Availability:
Availability of a product is measured as the ratio of total uptime of a product and
the combined time of total uptime and total downtime.
[b] Reliability:
Reliability relates to the length of time that the product will perform its technical
function satisfactorily. Reliability of a product is mostly explained in terms of
meantime between failure [MRBF] which is the average time that the product
functions from one failure to the next. If the MTBF is longer, the product is said
to be highly reliable.
[c] Maintainability:
Maintainability relates to correction of a product to bring it to service when it has
failed. Maintainability is measured by mean time to repair [MTTR].
If a product is promptly brought to correction and maintenance is carried out, then
the MTTR equals to downtime of the product.
SCOPE OFQUALITYCONTROLQualityControl believes that control must start with identification of customer
quality requirements and end only when the product has been placed in the hands
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of the customer who remains satisfied.
QualityControl guides coordinated action of people, machines and information to
achieve this goal.
Thus the Scope of QualityControl:
1) Marketing evaluates the level of quality which customers want and for which the
are willing to pay.
2) Engineering reduces this marketing evaluation to exact specifications.
3) Purchasing chooses contracts with. And retains vendors for parts and materials.
4) Manufacturing selects jigs, tools and processes for production.
5) Manufacturing supervision and shop operates exert a major quality during parts
making, subassembly, and final assembly.
6) Mechanical inspection and functional test check performance of products by
comparing conformance to specifications
7) Employees report regularly on the duty because their work is not rejected.
(8) Minimum or not wastage of material and other resources.
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NEED FOR QUALITYCONTROLUnless quality of the product/services is properly maintained it would not be
possible to obtain repeat orders through customers satisfaction. The following
illustrate need for controlling quality:
(1) Quality facilitates comparison between good and bad goods n services.
(2) Controlling quality ensures marketing of goods as per specification
(3) Good quality reduces dissatisfaction of customers.
(4) Good quality cuts down the rework and rejection costs.
(5) Longer life guaranteed to the products through improved quality.
(6) Standard spare parts are used ensuring continuous flow of production.
(7) Employees report regularly on the duty because their work is not rejected.
(8) Minimum or not wastage of material and other resources.
(9) Production of quality-perfect products.
(10) Quality specifications are strictly followed.
CONCLUSION
The purpose of qualitycontrol is to reduce this variability to an economical
minimum. It is possible to attain this objective through control of purchasing and
receiving by ensuring uniformity in incoming materials and parts. Control is
generally grouped under quality assurance activities.
The significance of qualitycontrol is, now, acknowledged at a large-scale level. It is
a critical prerequisite for promoting exports. Qualitycontrol is vital as it gives
benefits to producers, consumers and the society at huge. Consumers are now
tremendously quality conscious and they support quality products. They even insist
for superior quality goods for their safety and protection. This suggests the
importance of qualitycontrol. Even the survival of a manufacturing unit depends on
its ability to supply high quality goods to consumers. It gets capacity to compete
with rival producers through effective qualitycontrol.
Quality control aims at preventing the defects rather than detecting the defects.