Quality Control & SQC Quality control is an technique by means of which products of uniform acceptable quality are manufactured. SQC is defined as technique of applying statistical methods based on theory of probability to establish quality standards and to maintain it in the most economical manner. Causes of variation in Quality Chance causes Assignable causes Chance causes Causes vary at random, Independent of each other. Difficult as well as uneconomical to detect & eliminate them, natural to any manufacturing process . Beyond human control. Also called natural, permissible or allowable variation. Ex : Heterogeneity in material used. Assignable causes Non-Random , can be identified. May arrive at any stage of process. Can be detected & eliminated easily. Also called controllable or preventable variation. Ex : Defective RM, unskilled workers, worn equipments. Techniques of SQC Process Control : concerned with controlling the quality of product during production process only. It uses control charts. Product Control: It is concerned with controlling the quality of product by critical examination at strategic points. It is concerned with inspection of goods already produced. It makes use of sampling inspection plans . Process Control Control Charts Attributes/properties Colour, cracks, imperfections, surface appearance Subjected to qualitative measurements Acceptable or non- acceptable P chart, np chart, C chart Variables Diameter,length,thickness, resistance etc Subjected to quantitative measurements Control charts X bar charts, R charts A Process Is in Control If 1. no sample points outside limits 2. most points near process average 3. about equal number of points above and below centerline 4. points appear randomly distributed Control Charts Used for the study and control of repetitive processes Control charts for variables Xbar charts , R Charts Control charts for attributes P charts, np charts, C charts Control chart for variables Control chart for sample means X bar charts Control chart for sample ranges R charts Control chart for attributes Control chart for fraction defective p-chart Control chart for number of defectives np-chart Control chart for number of defects C-chart Product Control It is concerned with classification of raw-materials, semi-finished goods or finished goods into acceptable or rejectable items. It is concerned with the inspection of goods already produced to judge whether these are fit to be used or dispatched. Consequences of 100% inspection When quality of a product is tested by destructive testing ( Eg. Testing of electrical components), then 100% testing will spoil all products. Causes enormous fatigue which affects accuracy and judgement of inspectors. Handling of pdt. may cause defects or result in its deterioration. Cost of inspection may be very high. May be hazardous or even dangerous ( testing of pressure vessels). Terms in Acceptance sampling
1. Producer's risk () is the probability that a lot
containing acceptable quality level will be rejected . 2. Consumers risk () is the probability that a lot containing defective exceeding the LTPD will be accepted . 3. Acceptable Quality Level (AQL) is the maximum proportion of defectives that will make the lot definitely acceptable. 4. Lot tolerance percentage defective(LTPD) is the proportion of defectives that will a customer is willing to tolerate in accepted lots . Acceptance sampling Decisions about the quality of batches are made on the inspection of only a portion of the total number of items. If samples meets specifications, whole batch is accepted , if not batch is rejected or subjected to further inspection. It involves 2 types of risk producers risk & consumer risk. All parameters i.e. producers risk , consumer risk, AQL, RQL should be settled at the time of contract between producer and consumer. Types of Acceptance Sampling 1. Acceptance sampling by attributes Products are inspected on basis of GO and NOT GO gauges. Here actual measurement is done. If pdt meets specification , it is accepted , otherwise rejected however small be the error. EX. Pipe with very small crack may be rejected. used for plug gauges, snap gauges etc. Types of Acceptance Sampling 2. Acceptance sampling by variables Here actual measurement of dimensions or physical and chemical properties are done. It is detailed as compared to earlier. Time-consuming as compared to earlier. Types of Sampling plans Single sampling plan Double sampling plan Multiple (sequential) sampling plan OC Curve (AQL, Low Tolerance % defective,