IEQ Micro Project (22657)

SUBMITTED BY

Rushikesh Desale

Ritesh Patil

Atharva shinde

Aniket bhadane

T.Y.M.E.

GUIDED BY

PROF. P.B. YELMAME

MECHANICAL ENGINEERING DEPARTEMENT (0078)

K.K.WAGH POLYTECHNIC, NASHIK

2019-20

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CONTENT

Sr.No. Description Page No.

1 Acknowledgement 3

2 Introduction 4

3 Benefi ts of using Quali ty cont rol in Manufacturing 5

4 Methods to Implement Quali ty cont rol in Manufacturing 6

5 Advantages of Effective Quali ty cont rol 7

6 Quali ty cont rol in small scale industries 8

7 Basis of Quali ty cont rol 9

8 Cost of Quali ty cont rol 10

9 Resources 11

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ACKNOWLEDGEMENT
The success and the final outcome of this project required a lot of guidance and
assistance from many people and we are extremely privileged to have got this all along the
completion of our project. All that we have done is only due to such supervision and
assistance and we would not forget to thank them.

We respect and thank Mr P.B. Yelmame Sir for providing us an opportunity to do the
project work and giving us all support and guidance which made us complete the project duly.
We are extremely thankful to him for providing such although he had busy schedule
managing the corporate affairs a nice support and guidance.

We also owe our deep gratitude to him, as he took keen interest in our project work
and guided us all along, till the completion of our project work by providing all the necessary
information for developing a good system. We would not forget to remember librarians of the
collage for their encouragement and providing the needed resources and books till the
completion of our project work. We heartily thank our internal project guide and mentor for
his guidance and suggestions during this project work.

We are thankful to and fortunate enough to get constant encouragement, support and
guidance from all teaching staffs of Mechanical Department who helped us in successfully
completing our project work. Also, we would like to extend our sincere esteems to all staff in
different labs for their timely support.

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Intoduction
Quality Control In Manufacturing
 In manufacturing, quality control is a process that ensures customers receive products
free from defects and meet their needs. When done the wrong way, it can put
consumers at risk. For example, the recent defect found in Takata airbags resulted in
the biggest automotive recall in history. The recall includes almost 69 million airbag
inflators and may cost billions of dollars. The recall will last until the end of 2019 and
take until 2020 to resolve. Major recalls like these can be prevented through effective
quality control in manufacturing. Some common tools used to support quality control.
 Statistical process control (SPC) monitors and controls quality by tracking production
metrics. It helps quality managers identify and solve problems before products leave
the facility.
 Six Sigma uses five key principles to ensure products meet customers’ needs and have
zero defects.When supported by lean tools like Total Productive Maintenance (TPM),
5S, and Kaizen, most if not all defects can be eliminated.

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Benefits of Using Quality Control in Manufacturing

Customers expect and demand high-quality products. When customers receive quality
products you will:
• Increase customer loyalty
• Gain repeat business
• Gain new customers from referrals
• Maintain or improve your position in the market
• Improve safety
• Reduce liability risks
• Contribute to overall positive branding of your product
Manufacturers with quality control procedures in place are far less likely to face
product recalls or place customers at risk from poorly made products. The cost associated
with these recalls can be steep. Testament to this is the Takata recall, which is estimated to
cost the company between $7 and $24 billion.

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Methods to Implement Quality Control in Manufacturing

To implement an effective quality control program, first create and document your
approach to quality control. This includes:
• Defining the quality standards for each product
• Selecting the quality control method
• Defining the number of products/batch that will be tested
• Creating and training employees for quality control
• Creating a communication system for reporting defects or potential issues.Next, will need to
create procedures for handling defects. Consider the following:
• Will batches be rejected if defected items are found?
• Will there be further testing and potential repair work involved?
• Will production be halted to ensure that there are no more defective products created?
• How will new product versions be handled?
Finally, use a method like 5-Whys to identify the root cause of the defect, make any
needed changes, and ensure your products are defect free.

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Advantages of Effective Quality Control

a manufacturing facility has a good quality control system in place, they will benefit in
many ways. These benefits don't stop just at the manufacturing company, but extend to
customers, vendors, employees, and more. The following are some of the key advantages to
having an effective quality control system in place:
• Customer Loyalty - Quality control helps to reduce the risk of a defective product making it
into the hands of customers. Providing customers a consistently positive experience will
improve their loyalty to the brand. When
• Reduced Waste - Being able to identify quality issues quickly will reduce the amount of
waste produced due to defective products.
• Compliance In many manufacturing industries, there are compliance, environmental, and
other regulations that must be met. Quality control programs can focus on these areas to
ensure compliance.
• Customer Referrals - Customers who receive consistently high quality products are more
likely to refer their friends and family to that brand.
• Improved Safety - A defective product is often a dangerous product. Quality control can
find and eliminate potential safety issues early on.
• Employee Empowerment - In most quality control systems all employees are encouraged to
take steps to identify issues. This can help to empower employees, which can lead to
improved morale.
• Increased Profits - Allowing defective products to continue to be made can result in very
costly recalls, lost customers, and an overall drop in profitability.
• Corporate Image - Companies are often known for their great reliability. This
accomplishment starts with a great quality control department.
These are just the most tangible benefits of an effective quality control system in
manufacturing. There are also many secondary, advantages that a company will enjoy. Taking
the time to implement and improve quality control systems will help any business improve
over time.

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Quality Control in Small-Scale Industries

Although quality control is necessary for all units, yet it is more necessary for small-
scale units. This is because of the great use of manpower in small-scale industries during the
manufacturing processes. But, the application of quality control is difficult in them because
of several limitations like financial, technical and managerial. Quality implementation is total
organizational effort.

The successful implementation of quality control largely depends upon the quality of
raw materials, selection of machinery and equipment, designing, manufacturing, processes,
etc. Besides, the timely and required assistance from the Government organizations,
associations, and institutes also contribute to successful implementation of quality control. In
India, Bureau of Indian Standards (BIS) has been doing a yeoman job in determining the
quality of a large number of products by laying down various criteria for them.

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Basis of Quality Control

 Indian Standards specification.
 Quality marketing schemes.
 Company Standards in case of ancillary units.
 Any other standard specification prescribed by the Government or other purchasing
agencies.

The Indian Standards Specifications have been playing an important role in persuading
small-scale industries to adhere to the quality of their products.

For controlling quality of products manufactured by small units, the

following Indian Standards have been published so far:

 Methods of statistical quality control during the production period.

 Manual on basic principles of lot sampling; and
 Sampling inspection table.

Several State Governments have been operating quality marketing schemes and standards for
various products of small-scale industries. When the small units manufacture their products
according to the standards set, the Quality Marketing Centers of the Government stamp the
“Q” mark on their products. This is an assurance for the customers that the product has been
manufactured adhering to certain quality standards.

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Cost of Quality Control

Lastly, let us also address to an important aspect of quality control, i.e., cost involved in
ensuring quality products. In fact, it is difficult, if not impossible, to precisely define cost
incurred in quality assurance due to so many imponderables involved. But there is no
denying of the fact that it should be a minor proportion of the total product cost incurred.
How much minimum should be the proportion of quality cost to total cost depends upon
various factors?

Some of the important ones are:

 Type of product, its functional use and hazards involved in its use.
 The degree of quality awareness prevailing in the enterprise by implementation of the
concepts like Total Quality Management (TQM) and Quality Control (QC).
 Lastly, additional costs to be incurred for ensuring higher quality standards. It must be
kept in mind that there is no optimum value between quality and product cost.

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Resources
 https://www.graphicproducts.com/articles/quality-control-in-manufacturing/
 https://www.creativesafetysupply.com/articles/quality-control-in-manufacturing/
 https://www.newcastlesys.com/blog/an-introduction-to-quality-control-in-
manufacturing

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