Industrial Management (Unit-4)
Quality Control
Quality: According to International Organization for Standardization- Quality means the totality
of features and characteristics of a product or services that bears on its ability to satisfy stated or
implied needs.
Quality Control: It is a process of checking the products to ensure that they meet the required
quality standards and specifications.
It means the recognition and removal of the identifiable causes of defects and variations from the
established standards.
Objectives of Quality Control:
i) To assess the quality of raw materials, semi-finished goods and finished goods at
various stages of the production process.
ii) The ensure that the products conforms to the predetermined standards and
specifications.
iii) To suggest remedial measures in case of non conformation.
iv) To suggest suitable improvements in the quality of product without much increase in
the cost of production.
v) To develop quality awareness in the various sections of manufacturing unit.
vi) To reduce the wastage of raw materials, men and machines during the production
process.
Benefits / Advantages of Quality Control:
i) An efficient quality control system reduces the cost of production of the product by
minimizing wastage of materials and minimization of rework cost.
ii) The employees become quality conscious and their morale is improved.
iii) It ensures the maximum utilization of resources.
iv) Uniformity and reliability of products help in increase in sales.
v) Inspection cost and customers’ complaints are minimized.
vi) Increased consumer satisfaction.
Steps in Quality Control:
i) Design of the production system.
ii) Determination of the quality standards and specification.
iii) Control action.
iv) Inspection of produced products.
Statistical Quality Control ( SQC):
It is a scientific technique of controlling quality by means of statistical methods. It makes
inspection more reliable and less costly. It uses the following three scientific techniques –
a) Sampling Inspection
b) Analysis of data
c) Control charting.
Importance of SQC:
i) It gives an early signal of defects.
ii) It helps maintain good customer relations by ensuring high quality.
iii) It helps avoid unnecessary machine adjustments.
iv) It helps determining capability of manufacturing process.
v) The rework and scrap are minimized.
Control Charts: It is a graphical presentation of the collected information. A control chart
is a diagnostic technique.
Purpose and Advantages:
i) It indicates whether the process is in control or out of control.
ii) It detects the variation taking place in the process.
iii) It ensures about the product quality level.
iv) It gives early warning about the defects.
Types of Control Charts:
Control Chart
Process Control Production Control
Variables Attributes Variables Attributes
R Chart p-Chart np-Chart C-chart
Chart
CONTROL CHARTS FOR VARIABLES:
Following are the control charts for variables:
1) – chart or Mean Chart: In this chart a number of items are collected at random at
different intervals of time. Following steps are used:
a) Preparation of Mean value(X) and Range (R)
Let us assume that sample size is K=4 whose lengths are L1, L2, L3, L4
Then, Mean = (L1+L2+L3+L4)/4 or =∑ x /4
Range (R) = Lmax - Lmin
b) Calculation of mean of Means
= ∑ /n
Where ∑ = sum of mean of samples and n = number of samples
represents the central line of the X- chart
c) Calculation of Upper Control Unit (UCL) and Lower Control Unit (LCL)
UCL = + A2 R
LCL = - A2 R
Where A2 is limit average
2) R – Chart:
In case, of R – chart
Range (R) = Highest Value – Lowest Value
Central Line (CL) = = ∑R/n where n = no. of samples
Upper Control Limit ( UCL) = D4
Lowest Control Unit (LCL) = D3
CONTROL CHARTS FOR ATRRIBUTES:
Following are the control charts for attributes:
1) p – chart (Control chart of fraction):
this is a fraction defective chart or % defective chart, where each item is classified as
non-defective and defective.
Central Line = =
UCL =
LCL =
2) n-p Chart ( Control Chart of defective items)
Central Line = n =
UCL =n
LCL =n
3) C chart ( Control chart of no. of defects per unit)
Central Line = =
UCL =
LCL =
SAMPLING AND SAMPLING PLANS
Sampling: Sampling is an act of drawing samples from a batch on random basis.
Sampling Plans:
1. Single Sampling Plan: In this plan , a lot is accepted or rejected on the basis of single
sample drawn from that lot.
Method:
i) A single sample of size n is selected from the lot.
ii) The sample is inspected and the defected components are taken out from the lot.
iii) If the no. of defected items exceed the acceptance no. C, then the lot is rejected.
iv) If the lot is rejected then each item of the lot is inspected and the defective items
are replaced.
Let x = no. of defective items.
C = acceptance number, R = rejection number
a) If x<= C accepted
b) If x>C rejected
c) If C < x < R take the next sample
2. Double Sampling Plan: When it is not possible to decide about the lot on the basis of the
first sample then a second sample is drawn out of the same lot. The decision to accept or
reject the lot is taken on the basis of the combined results of first and second samples.
Method:
Given C1 and C2 are acceptance numbers and C2 > C1
i) Inspect a sample for size n1 and count defective parts K1
ii) We have the three possibilities:
a) K1 <= C1 accept the lot
b) K1 > C1 reject the lot
c) C1 < K1 <= C2 no decision
In case of possibilities ‘c’
C1) draw another sample of size n2 . Total sample size = n1+n2
C2) defective items in second sample K2. Total defective items = K1+K2
C3) if K1+K2 <= C2 accept the lot
if K1+K2 > C2 reject the lot
3 ) Sequential Sampling Plan: It is of the following two types:
A) Multiple Sampling Plan: Following procedure is adopted:
i) Inspect the first sample and count the no. of defects.
ii) There are three possibilities:
a) The no. of defects is very small accept the lot
b) The no. of defects is very large reject the lot
c) Border line and un-decisive no decision
In case of ‘c’ draw a second sample and inspect, combined no. of defects
both samples, there are three possibilities:
C1) no. of defects is very small accept the lot
C2) no. of defects is very large reject the lot
C3) border line and un-decisive no decision
Repeat the same procedure for the third sample or fourth sample.
B) Sequential Sampling Plan:
It is plan in which size is increased by one item at a time till the sample
becomes large enough, and contain a large no. of defective items to decide
whether the lot should be accepted or rejected.
TOTAL QUALITY MANAGEMENT (TQM)
Definition: The total quality management is a total approach to put quality in every aspects of
management. It is total organization working as a team to meet the customer needs and
expectation by using systematic approach to continuous improvement.
Continuous Customer
Improvement Focus
TQM
Prevention of Universal
Defects Responsibility
for Quality
Elements of TQM Concept
Essentials of TQM Focus:
i) Leadership
ii) Quality policy and quality cost
iii) Organizational Structure
iv) Employee Involvement
v) Supplier selection and development
vi) Use of continuous plan
vii) Customer satisfaction
viii) Recognition and reward
Characteristics of TQM:
1. Totality: It refers all areas and functions, all activities and all employee for optimum quality
at all times.
2. Improvements; It specifies the ability which leads to development.
3. Foundation: This concerns with company’s organizational structure and system. It ensures
the scope of quality functions within organization.
4. Documentation: It is integrated people-machine-information relations to make the TQM
effort happen.
Evolution of TQM:
Insp.
QA
QC
TQM
Evolution of TQM includes Inspection, Quality Control, Quality Assurance and TQM
1. Inspection: It is tool for checking quality. In inspection organization focuses on:
i) Indentifying non-conformities.
ii) Removing defects
iii) Replacing defective items with the non-defective items.
2. Quality Control: Quality control focuses on the following points:
i) Process performance data
ii) Quality Planning
iii) Statistical Tools
iv) Control instruments
3. Quality Assurance: In this following points are focused upon:
i) Documentation
ii) System certification
iii) Quality manuals
iv) Quality Costs
4. TQM: In this focus is upon:
i) Customer
ii) Employer and employee involvement
iii) Continuous improvement
iv) Performance management
TQM Models: There are various models adopted by different companies for implementing
TQM:
a) TQM Transition Model: In this model all initiatives are focused on customers and the
customer is treated as a key factor. All the needs of customers are understood and fulfilled. The
model is represented as below:
VISION
Customer
Focus
Continuous Improvement Involvement of All
b) Integrated TQM Model: This model ensures that without completing one’s responsibility,
next responsibility will not be taken. Therefore in this model evaluation process, auditing and
performance appraisal do not find a place.
Management Leadership
Customer
Focus
Product/ Process Excellence Human Resource Excellence
c) Operational TQM Model: This model is based on participation and team work. It is focused
on the self motivated and self empowered teams consisting of multi skilled workers.
Management Support and Commitment
Leadership
Quality
Management
System
Total Participation Quantitative/ Qualitative
Self Empowered Team Problem Solving Tools
