QUALITY CONTROL and INSPECTION

QUALITY:- IT IS DEFINED AS “fitness for purpose”.

QUALITY is a measure of general excellence” of the product.
• Manufacturing quality focuses on product features
– Conformance, performance, reliability, features
• Service organizations produce products features that must be
experienced
– Quality often defined by perceptional factors like courtesy, friendliness,
promptness, waiting time, consistency
Crosby defined as “Quality is conformance to requirement or specifications”.
Juran defined as “Quality is fitness for use”.
 Factors affecting the quality of product

 Men
 Machines
 Raw material used
 Mfg. processes
 Dimensional variations in the product
 Various stages of inspection
 Types of material handling systems
Quality characteristics-
It can be defined as, ‘ any physical or chemical property such as dimension,
temp., pressure, taste, odour or other such requirement used to define
the nature of product or service.”
Classification of characteristics:-
According to analysis: directly measurable – length, weight
non measurable – flaws , cracks
 Quality specification
Standard specification means standard bodies formulate
 Consumer specification : his paricular needs & if the
producer agrees
 Company specification: mfg product on based on its own
specifications & consumer accepts them.
 Contract specification: mutual contract between company
& consumer accepts.
 Process specification: specify the process to produce a
particular product
 Test specification: need & scope of test, purpose of test,
test procedure, test instruments.
 QUALITY CONTROL
QUALITY CONTROL is defined as,” an effective system for integrating
the quality development, quality maintenance and quality improvement
efforts of various groups In an organization, so as to enable production
and services at the most economical levels, which allows full customer
satisfication”.
Objectives of quality control
 Improved income
 Product Cost reduction
 Interchangeability in mass production
 Customer,s satisfication
 Optimum quality: Optimum quality at min. price
 Intergration of quality effects
 Quality mindness : quality mindness among the workers
Seven Tools for Quality Control
1. Pareto charts
2. Check sheets
3. Cause and effect diagram
4. Scatter diagrams
5. Histogram
6. Graphs or flow charts
7. Control charts
 Quality of design
Quality of design is defined as,’’ the quality specified
by design engineer, on behalf of customer”.
Factors governing or controlling quality of design:
 Type of customer in market
 Economical considerations
 sp. Requirements such as environmental
conditions, realibility, improvement in continuity
service, strength, life, interchangebility.
 Quality of conformance
Quality of conformance is concerned with, how well the mfg.
product conforms to the quality of design.”
Factors governing or controlling quality of design:
• Skill of workers
 Raw materials
 Machines
 Raw material used
 Mfg. processes
 Effective inspection
 Various stages of inspection
 Types of material handling systems
 Quality of performance
Quality of performance is concerned with, how well the mfg. product gives its
performance.”
Quality of performance is depend upon Quality of design & Quality of
conformance
Quality of design + Quality of conformance = Quality of performance
 Relibility
Relibilty is defined as, “the probability of a product that, it will give
satisfactory performance over sufficient time period.”
Relibilty is also defined as, “the probability of a product functioning in the
intended manner over its intended life.”
Relibilty can be the ability of a product to perform a required function under
stated conditions for a stated period of time without failure.
RT = e-ʎT
RT = Relibilty over life ‘T’
ʎ failure rate i.e . No. of failures per unit time
Cost of quality
 Value of quality
Value of quality is defined as , “direct or indirect returns gained by the
company due to implemented missions of quality control”.
 Inspection

• 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. It
helps to control quality, reduces manufacturing costs, eliminate scrap
losses and assignable causes of defective work.
“the act of checking of material, products or components of products at
various stages of manufacturing.”
• Objectives of Inspection
1. To detect and remove the faulty raw materials before it undergoes
production.
2. To detect the faulty products in production whenever it is detected.
3. To bring facts to the notice of managers before they become serous to
enable them discover weaknesses and over the problem.
4. To prevent the substandard reaching the customer and reducing
complaints.
5. To promote reputation for quality and reliability of product
• Types of Inspection
1. Floor inspection
2. Centralized inspection
3. Combined inspection
4. Functional inspection
5. First piece inspection
6. Pilot piece inspection
7. Final 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. Inspectors have to be highly
skilled. This method of inspection minimize the material handling, does not
disrupt the line layout of machinery and quickly locate the defect and readily
offers field and correction.
Advantages
1.Detection of errors of the source reduces scrap and rework. 2. Correction is
done before it affects further production, resulting in saving cost of unnecessary
work on defective parts. 3. Material handling time is reduced. 4. Job satisfaction
to worker as he can’t be held responsible for bad work at a later date. 5. Greater
number of pieces can be checked than a sample size. 6. Does not delay in
production.
Disadvantages 1. Delicate instruments can be employed. 2. Measuring or
inspection equipment have to be recalibrated often as they are subjected to
wear or dust. 3. High cost of inspection because of numerous sets of inspections
and skilled inspectors. 4. Supervision of inspectors is difficult due to vibration. 5.
Pressure on inspector. 6. Possibility of biased inspection because of worker.
2. CENTRALISED 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. Centralised inspection
may locate in one or more places in the manufacturing industry.
Advantages 1. Greater degree of inspection due to sensitive equipment. 2. Less
number of inspectors and tools. 3. Equipment needs less frequency of
recalibration. 4. Cost of inspection is reduced. 5. Unbiased inspection. 6.
Supervision of inspectors made possible. 7. No distraction to the inspector.
Disadvantages 1. Defects of job are not revealed quickly for prevention. 2.
Greater material handling. 3. High cost as products are subjected to production
before they are prevented. 4. Greater delay in production. 5. Inspection of heavy
work not possible. 6. Production control work is more complicated. 7. Greater
scrap
3. 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.
4. 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.
5. FIRST PIECE OR FIRST-OFF INSPECTIONS 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.
6. 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 aeroplanes etc., and modification are
design or manufacturing process is done until satisfactory performance is assured or
esta
7. 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.
Seven Tools for Quality Control
1.Pareto charts
2. Check sheets
3. Cause and effect diagram
4. Scatter diagrams
5. Histogram
6. Graphs or flow charts
7. Control charts
Pareto charts- Pareto charts help prioritize by
arranging them in decreasing order of importantce.
 Check sheets

A checklist is a form used to record the frequency of occurrence of certain product or

service characteristics related to quality. The characteristics may be measurable on a
continuous scale such as weight, diameter, time or length.
Cause and effect diagram /fishbone/ISHIKAWA diagram
 Scatter diagrams

It often indicates the relationship between two variables. They are often used as
follow-ups to a cause and effect analysis to determine whether a stated cause
truly does impact the quality characteristics.
 Histogram

• A histogram is a graph that shows the frequency of numerical data using

rectangles. The height of a rectangle (the vertical axis) represents the
distribution frequency of a variable (the amount, or how often that
variable appears).
 Control Charts
• Variable control charts:
It is one by which it is possible to measures the quality
characteristics of a product. The variable control charts are X-
BAR chart, R-BAR chart, SIGMA chart.
• Attribute control chart:
It is one in which it is not possible to measures the quality
characteristics of a product, i.e., it is based on visual inspection
only like good or bad, success or failure, accepted or rejected.
The attribute control charts are p-charts, np-charts, c-charts, u-
charts. It requires only a count of observations on characteristics
e.g., the number of non-conforming items in a sample
Graphs or flow charts