INSPECTION

REPORTER: MATURAN, JOSHUA

INTRODUCTION

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 inspection and test unit is responsible for appraising the quality of incoming raw
materials and components as well as the quality of the manufactured product or service. It
checks the components at various stages with reference to certain predetermined factors
and detecting and sorting out the faulty or defective items. It also specified the types of
inspection devices to use and the procedures to follow to measure the quality
characteristics.

Inspection is the most common method of attaining standardization, uniformity and quality
of workmanship. It is the cost art of controlling the production quality after comparison with
the established standards and specifications. It is the function of quality control. If the said
item does not fall within the zone of acceptability it will be rejected and corrective measure
will be applied to see that the items in future conform to specified standards.
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.

Purpose of Inspection

1. To distinguish good lots from bad lots.

2. To distinguish good pieces from bad pieces.
3. To determine if the process is changing.
4. To determine if the process is approaching the specification limits.
5. To rate quality of product.
6. To rate accuracy of inspectors.
7. To measure the precision of the measuring instrument.
8. To secure products-design information.
9. To measure process capability.
 Types of Inspection

1. 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. These
inspectors move from machine to machine and from one to the other work centres.
Advantages
1. Detection of errors of the source reduces scrap and rework
2. Material handling time is reduced.
3. Does not delay in production.
Disadvantages
1. Measuring or inspection equipment have to be recalibrated often as they are subjected to
wear or dust.
2. High cost of inspection because of numerous sets of inspections and skilled inspectors.
3. Pressure on inspector.
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.
 Methods of Inspection

1. 100% INSPECTION
This type will involve careful inspection in detail of quality at cach strategic point or stage of manufacture
where the test is involved is non-destructive and every piece e is separately inspected. It requires more
number of inspectors and hence it is a costly method. There is no sampling error. This is subjected to
inspection error arising out of fatigue, negligence, difficulty of supervision etc. Hence, coropleter accuracy
of influence is seldom attained. It is suitable only when a small number of pieces are there or a very high
degree of quality is required. Example: Jet engines, aircraft, medical and scientific equipment..

2. SAMPLING INSPECTION
In this method randomly selected samples are inspected. Saruples taken from different patches. of
products are representatives. If the sample proves defective, the entire concerned is to be rejected or
recovered. Sampling inspection is cheaper and quicker. It requires less number of Inspectors. It is
subjected to sampling errors but the magnitude of sampling error can be estimated. In the case of
destructive test, random or sampling inspection is desirable. This type of inspection governs wide
currency due to the introduction of automatic machines or equipments which are less susceptible to
chance variable and hence require less inspection, suitable for inspection of products which have less
precision importance and are less costly. Example: Electrical bulbs, radio bulbs, washing machine etc.
QUALITY CONTROL
Introduction

Quality Control (QC) may be defined as a system that is used to

maintain a desired level of quality in a product or service. It is a
systematic control of various factors that affect the quality of the
product. It depends on materials, toois, machines, type of labour,
working conditions etc.
QC is a broad term, it involves inspection at particular stage but
mere inspection does not mean QC. As opposed to inspection, in
quality control activity emphasis is placed on the quality future
production. Quality control aims at prevention of defects at the
source, relies on effective feedback system and corrective action
procedure. Quality control uses inspection as a valuable tool.
 Types of Quality Control
QC is not a function of any single department or a person. It is the primary responsibility of any
supervisor to turn out work of acceptable quality, Quality control can be divided into three main sub
areas, those are:
1. Off-line quality control: Its procedure deal with measures to select and choose controllable
product and process parameters in such a way that the deviation between the product or process
output and the standard will be minimized. Much of this task is accomplished through product and
process design.
2. Statistical process control: SPC involves comparing the output of a process or a service with a
standard and taking remedial actions in case of a discrepancy between the two. It also involves
determining whether a process produce a product that meets desired specification or requirements.
On-line SPC means that information is gathered about the product, process, or service while it is
functional. The corrective action is taken in that operational phase.
3. Acceptance sampling plans: A plan that determines the number of items to sample and the
acceptance criteria of the lot, based on meeting certain stipulated conditions (such as the risk of
rejecting a good lot or accepting a bad lotj is known as an acceptance sampling plan.
 Steps of Quality Control

Following are the steps in quality control process:

1. Formulate quality policy.
2. Set the standards or specifications on the basis of customer's preference, cost
and profit.
3. Select inspection plan and set up procedure for checking.
4. Detect deviations from set standards of specifications.
5. Take corrective actions or necessary changes to achieve standards.
6. Decide on salvage method i.e., to decide how the defective parts are disposed of,
entire scrap or rework
7. Coordination of quality problems.
8. Developing quality consciousness both within and outside the organization.
9. Developing procedures for good vendor-vendee relations.
 Objectives of Quality Control

1. To improve the companies income by making the production more acceptable to

the customers, i.e., by providing long life, greater usefulness, maintainability etc.
2. To reduce companies cost through reduction of losses due to defects,
3. To achieve interchangeability of manufacture in large scale production.
4. To produce optimal quality at reduced price.
5. To ensure satisfaction of customers with productions or services or high quality
level, to build customer goodwill, confidence and reputation of manufacturer.
6. To make inspection prompt to ensure quality control.
7. To check the variation during manufacturing.
8. The broad areas of application of quality control are incoming material control,
process control and product control.
 Benefits of Quality Control

• Improving the quality of products and services.

• Increasing the productivity of manufacturing processes, commercial
business, corporations.
• Reducing manufacturing and corporate costs.
• Determining and improving the marketability of products and services.
• Reducing consumer prices of products and services.
• Improving and/or assuring on time deliveries and availability.
• Assisting in the management of an enterprise.