UNIT-4

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UNIVERSITY SYLLABU
Quality Control: Meaning, process control, SQC control charts, single, double and
sequential sampling, Introduction to TQM.
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QUALITY CONTROL

The quality is defined as the degree to which a product meets the requirements of customers.
The quality of a product consists of the following attributes:

i. Appearance of product
ii. Product design
iii. Performance of the product
iv. Reliability of the product
v. Durability of the product
vi. Serviceability
vii. Maintainability
viii. Suitability from customer‟s point of view
ix. Degree to which it conforms the product specifications
x. Marketing and after sales services.

INSPECTION
Inspection is a function of quality control. That is, inspection finds out whether the
products manufactured are as per specifications. Inspection rejects bad products and
accepts good products.
Objectives of inspection
The following are the objectives of inspection.

1. To find out and remove faulty material before it is machined. This is to avoid wastage
of material.
2. To remove defective products as soon as the defect occurs. This is to prevent
further working on the defective products.
3. To discover defects for corrective action before they become serious.
4. To ensure that defective products do not reach the customer.
5. To earn goodwill of the customer.
6. To ensure proper functioning of assembled products.
7. To ensure safe working of the products.
8. To locate defects in design.

MEANING AND DEFINITION OF QUALITY

CONTROL

Meaning

The term „Quality Control‟ consists of two words „Quality‟ and „Control‟. Thus „quality
is defined as fitness for purpose‟.

The quality of an article may include such elements as design, size, materials, chemical
composition, mechanical functioning, electrical properties, finish and
appearance.

Control is referred to as the comparison of actual results (finished product) with the predetermined
standards and specifications.
 Thus control is a system for measuring and checking (inspecting) a phenomenon. Control is the
correction in the quality of the product, when deviations in the quality are more than expected
in the process.

Definition
Quality control is the process of control where the management tries to conform the quality of
product in accordance with the pre-determined standards and specifications.

The quality control is defined as a process of checking the products to ensure that they meet the
required quality standards and specifications. The quality control may also be defined as industrial
management technique or group of techniques by means of which products of uniform
acceptable quality are manufactured. (Alford and Beatty)

According to J. A. Shobin, quality control means the recognition and removal of the
identifiable causes of defects and variations from the pre-sets standards.
OBJECTIVES OF QUALTITY CONTROL
Following are the objectives of quality control:

1. To assess the quality of raw materials, semi-finished goods and finished products
at various stages of production process.
2. To see whether the product confirms to the predetermined standards and specifications
or not.
3. In case the product does not satisfy the standards, then to suggest necessary
remedial steps.
4. To suggest suitable improvements in the quality of product without much increase in
the cost of production. For this purpose, new techniques in methods and machines may
be applied.
5. To develop quality consciousness in various sections of manufacturing unit.
6. To reduce the wastage of raw materials, men and machine during the process
of production.
 BENEFINTS /ADVANTAGES OF QUALITY CONTROL
Following are the benefits of quality control:

1. An efficient quality control system reduces the cost of production of the product due
to following factors:
(i) Reduction in wastage of raw material
(ii) Large-scale production
(iii )Minimization of rework cost of substandard goods.
2. By quality control programme, the employees become quality conscious, i.e., the
morale of employees is improved.
3. There is maximum utilization of resources, i.e., the necessary control over the
machine, equipment, men and materials and all other resources is exercised.
4. Uniformity and reliability of products help in increasing sale.
5. Inspection costs and customers complaints are minimized.
6. Consumers get the quality product of standard specifications, i.e., there is
consumers satisfaction.

S. No. Inspection Quality Control

1. It is one of the functions of quality It is a system of integrating quality
Control development, quality maintenance and
quality improvement
2. It finds out whether the products It aims at production of only quality
manufactured are acceptable or not. products
3. It is concerned with detection of It is concerned with prevention of defects.
defects of products already made.
4. It does not deal with any corrective It finds out the causes of poor quality. It
action. takes suitable corrective action.
5. It does not control production process. It controls production process.

PROCESS CONTROL
Process control is the active changing of the process based on the results of process
monitoring. Once the process monitoring detects an out of control situation, the person
responsible for the process makes a change to bring the process back into control.
1. Out of Control Action Plans (OCAPS) detail the action to be taken once an out of
control situation is detected.

2. Advance Process Control Loops (APCL) are automated changes to the process that
are programmed to correct the size of the out of control measurement.

Variation in the production process leads remove quality defects and lack of production consistency.
The Intel Corporation, the world‟s largest and most profitable manufacturer of microprocessors, has
implemented a program it calls “copy exactly” at all its manufacturing facilities.

The idea is whether the chips are made in Arizona, New Mexico, Ireland, or any of its other
plants they are made in exactly the same way.

This means using the same equipment, the same exact materials and workers performing the
same tasks in the same order. When a water quality was found to be of different at one facility,
Intel instituted a purification system to eliminate any differences.

Common causes of Variation: Common causes of variations are based on random causes that
we cannot identify. An important task in quality control is to find out the range of natural
random variation in a process.

E.g. if the average bottle of a soft drink produced by ABC Ltd. contains 16 Ounces of liquid we
may find out that the amount of natural variation is between 15.8 and 16.2 ounces. This type of
difference is completely normal. We would monitor the process to make sure that the amount
stays within this range.

Assignable Cause of Variation: This type of variation can be precisely identified

and eliminated. Eg.

- Poor quality of raw material,

- An employee needs more training,
- A machine in need of repairs.
 In each of these cases the problem can be identified and corrected. In the case of soft
drinks bottle filled with 15.6 Ounces of liquid would signal a problem and machine needs
to be adjusted.

Process control can be divided into two categories as follows:

1. Discreet Process: These are motion based such as automotive production , robotic
assembly, Packaging application etc. These are characterized as discreet process control.

Discreet manufacturing process is mostly automated. It uses Computer Numeric Control

(CNC) Computer Aided Design (CAD) Computer Aided Manufacturing (CAM), Copying
machines and robotics etc.

2. Continuous Process: These require that specific quantities of raw materials be combined
in specific ways for particular durations tom produce an intermediate or end product such as
chemical, fuels, Plastics and food items beverages and medicines etc. Continuous process
control use Programmable Logic Controller (PLC), Distributed Control System (DCS) ,
Supervisory Control and Data acquisition (SCADA) system, etc.

CONTROL CHARTS
A control chart is a graphical presentation of the collected information. The information
pertains to the measured or otherwise judged quality characteristics of the items or the
samples. Therefore, a control chart is a diagnostic technique. A control chart detects
variations in the processing and warns if there is any departure from specified tolerance
limits.

Control charts are the most important statistical tools for data analysis in quality control of
manufactured products.

Advantages of Control charts

1. It indicates whether the process is in control or out of control at a particular point of time.
 2. It ensures level of quality and builds up the reputation of the enterprise due to customer‟s
satisfaction.
3 It detects unusual variables taking place is a period.
4 It helps in reducing the rejections. It warns in time so that process can be rectified in time.
5 It helps in setting tolerance limits.

Statistical Factors Based on Normal Distribution

Sample size 2 3 4 5 6 7 8 9 10

A2 1.88 1.023 0.729 0.577 0.483 0.419 0.373 0.337 0.308

D3 0 0 0 0 0 0.076 0.136 0.184 0.219
D4 3.263 2.574 2.2824 2.114 2.004 1.924 1.860 1.814 1.777
Control Chart for Variables

Calculation procedure
1. Calculate average X and range R for each group
i. A number of samples of items manufactured are collected at regular intervals (say 1 or 2 hours)
ii. Their quality characteristics (diameter, thickness, weight, length etc. ) are measured.
iii. For sample, mean value and the range is calculated.
For example if sample size is of 5 items and dimensions are X1, X2, X3, X4, and X5

X1+X2+X3+X4+X5
The Sample average X= -------------------------

The range will be R= Highest value –Smallest value

2. Calculate Grand Average X and Average Range

R. X is the average of X value for each group.
X
X = ---------------------
 N
Where X = Average of Sample mean or average

And n = Number of observations, or subgroup

Similarly, the average R, is the sum of the ranges of the subgroup or observations divided by the
number of sub group
R
R= ---------------
n

3. Calculate Control Charts for X chart:

Upper Control Limit U C L for X = X + A2 R,

Lower Control Limit L C L for X = X – A2 R.

4. Calculate Control Limits for R Chart:

U C L for R = D4 R
L C L for R = D3 R

The value of A2, D3, D4 are based on normal distribution and can be found out from
standard table for a particular sample size.

5. Plot X and R chart:

i. Central line on the X chart should be solid horizontal line at X.
ii. The upper and lower control limits for X should be drawn as dotted horizontal lines
at computed values.
iii. Similarly for R chart central solid horizontal line will indicate R, and
iv. The control limits are shown by dotted horizontal line at computed value
v. if the size of sample is 6 or less, the lower control limit for R is zero.
Points outside the control limits are indicated with cross on the X chart, and the points
outside the limits on R chart by a circle
Control Chart for Attributes

1. Control Chart for Fraction Defectives (P- Chart)

Fraction defective may be defined as the ratio of the number of defective articles in
any inspection to the total number of articles actually inspected.
i. Take adequate number of samples.

ii. Find number of defective pieces found

iii. Calculate fraction defective

P/N

n
iv. Calculate P (1-P)
U C L of P = P+ 3 ----------
n
CL=P

P (1-P)
L C L of P = P + 3 -------------
n

2. C- Chart (Number of Defects per Unit)

In number of cases it is more convenient to work with number of defects per unit rather than
fraction defective. For example number of defects in a bus body , air plane , TV set, etc.
C- chart deals with the defects in the piece or unit of product manufactured.
i. Samples are taken at regular intervals

ii. It may be a length(wire) , or an area( piece of cloth)

iii. Number of defects are counted

iv. Calculate C.

Total number of defects in all samples

C = ------------------------------------------------------------
 Total number of samples observed

U C L of C = C + 3 C

CL= C

L C L of C = C + 3 C