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Assignment of production and

operation management

SUBMITTED BY – JATIN
SUBMITTED TO – MS. GUNEET
ROLL NO - 1921913
SEMESTER -6
SECTION - BBA(C)
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QUESTION – Acceptance sampling

,benefits and objectives of sequencing ?

-acceptance sampling
One method of controlling the quality of a product is 100% inspection
which requires huge expenditure in terms of time, money and labour.
Moreover due to boredom and fatigue involved in repetitive inspection
process, there exists a possibility to overlook and some defective
products may pass the inspection point.

Also when the quality of a product is tested by destructive testing (e.g.,

life of a candle or testing of electrical fuses) then 100% inspection shall
destroy all the products.

The alternative is statistical sampling inspection methods. Here from

the whole lot of products/items to be inspected, some items are
selected for inspection.

If that sample of items conforms to be desired quality requirements

then the whole lot is accepted, if it does not, the whole lot is rejected.
Thus the sample items are considered to be the representative of the
whole lot. This method of acceptance or rejection of a sample is called
Acceptance Sampling.
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In general acceptance sampling method proves to be economical and

is used under the assumption when the quality characteristics of the
item are under control and relatively homogeneous.

Classification of Acceptance Sampling:

Depending upon the type of inspection acceptance sampling
may be classified in two ways:
(i) Acceptance sampling on the basis of attributes i.e. GO and NOT
GO gauges, and

(ii) Acceptance sampling on the basis of variables.

In acceptance sampling by attributes, no actual measurement is done

and the inspection is done by way of GO & NOT GO gauges. If the
product conforms to the given specifications it is accepted, otherwise
rejected. The magnitude of error is not important in this case.

For example if cracks is the criteria of inspection/the products with

cracks will be rejected and without cracks accepted the shape and size
of the cracks shall not be measured and considered.

In acceptance sampling by variables, the actual measurements of

dimensions are taken or physical and chemical testing of the
characteristics of sample of materials/products is done. If the results
are as per specifications the lot is accepted otherwise rejected.

Terms Used in Acceptance Sampling:

Following terms are generally used in acceptance sampling:
(i) Acceptable Quality Level (AQL):
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It is the desired quality level at which probability of a acceptance is

high. It represents maximum proportion of defectives which the
consumer finds acceptable or it is the maximum percent defectives
that for the purpose of sampling inspection can be considered
satisfactory.

(ii) Lot Tolerance Percent Defective (LTPD) or Reject able

Quality Level (RQL):
It is the quality level at which the probability of acceptance is low and
below this level the lots are rejected. This prescribes the dividing line
between good and bad lots. Lots at this quality level are considered to
be poor.

(iii) Average outgoing Quality (A.O.Q):

Acceptance sampling plans provides the assurance that the average
quality level or percent defectives actually going to consumers will not
exceed certain limit. Fig 9.2 demonstrates the concept of average
outgoing quality related with actual percent defectives being produced.

The AOQ curve indicates that as the actual percent defectives in a

production process increases, initially the effect is for the lots to be
passed for acceptance even though the number of defectives has gone
up and the percent defectives going to the consumer increases.
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If this upward trend continues, the acceptance plan beings to reject

lots and when lots are rejected, 100% inspection is followed and
defective units are replaced by good ones. The net effect is to improve
the average quality of the outgoing products since the rejected lots
which to are ultimately accepted contain all non-defective items
(because of 100% inspection).

(iv) Operating Characteristic Curve or O.C. Curve:

Operating characteristic curve for a sampling plan is a graph between
fraction defective in a lot and the probability of acceptance. In practice
the performance of acceptance sampling for distinguishing defectives
and acceptable or good and bad lots mainly depends upon the sample
size (n) and the number of defectives permissible in the sample.

The O.C. curve shown in Fig. 9.4 is the curve of a 100 percent
inspection plan is said to be an ideal curve, because it is generated by
and acceptance plan which creates no risk either for producer or the
consumer. Fig. 9.3 shows the O.C. curve that passes through two
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stipulated points i.e. two pre-agreed points AQL and LTPD by the
producer and the consumer.

Usually the producer’s and consumer’s risks are agreed upon Fig. 9.4:
and explicitly recorded in quantitative terms.

This leads to following two types of risks:

 

The merit of any sampling plan depends on the relationship of

sampling cost to risk. As the cost of inspection go down the cost of
accepting defectives increases.

Characteristics of O.C. Curve:

(i) The larger the sample size and acceptance number steeper will be
the slope of O.C. curve.

(ii) The O.C. curve of the sampling plans with acceptance number
greater than zero are superior to those with acceptance number as
zero.
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(iii) Fixed sample size tends towards constant quality production.

Advantages of Acceptance Sampling:

(i) The method is applicable in those industries where there is mass
production and the industries follow a set production procedure.

(ii) The method is economical and easy to understand.

(iii) Causes less fatigue boredom.

(iv) Computation work involved is comparatively very small.

(v) The people involved in inspection can be easily imparted training.

(vi) Products of destructive nature during inspection can be easily

inspected by sampling.

(vii) Due to quick inspection process, scheduling and delivery times

are improved.

Limitations of Acceptance Sampling:

(i) It does not give 100% assurance for the confirmation of
specifications so there is always some likelihood/risk of drawing
wrong inference about the quality of the batch/lot.

(ii) Success of the system is dependent on, sampling randomness,

quality characteristics to be tested, batch size and criteria of
acceptance of lot.

Producer’s and Consumer’s Risk:

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The acceptance or rejection of the whole batch of products in

acceptance sampling depends upon the results of the sample
inspected. There is always a chance that a sample may not be true
representative of the batches or lots from which it is drawn.

This leads to following two types of risks:

(i) Producer risk.

(ii) Consumer risk.

(i) Producer Risk (α):

It is the small probability of a lot/batch being good or even better
acceptable quality level (AQL) but yielding a bad sample and thus
getting rejected. So this probability of rejection of a good lot which
otherwise would have been accepted is known as producer’s risk (α).

(ii) Consumer Risk (β):

It is the probability of a batch/lot being bad or worse than the limiting
quality (LQ) but yielding a good sample and getting accepted. So this
probability of a defective lot being accepted which otherwise would
have been rejected is known as consumer risk (β)
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BENEFITS OF SQC
1) It provides a means of detecting error at inspection.
2) It leads to more uniform quality of production.
3) It improves the relationship with the customer.
4) It reduces inspection costs.
5) It reduces the number of rejects and saves the cost of material.
6) It provides a basis for attainable specifications.
7) It points out the bottlenecks and trouble spots.
8) It provides a means of determining the capability of the
manufacturing process.
9) It promotes the understanding and appreciation of quality
control.

Improsys's strategic approach to problems make us understand

the root causes of problems and helps our customer to come up
with a long lasting and effective solution.
With our expertise in understanding the business and its all
aspects we provide solutions that will satisfy our customers
deeply. Improsys has successfully implemented the quality
control solutions in various organizations.

The main advantages of SQC are as follows

(i) It gives an early warning of defects. It provides a means of detecting

errors at inception.
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(ii) Rework and scrap are minimized. Statistical Quality Control avoids the
need for and costs of cent per cent inspection by pointing out trouble
spots.

(iv) SQC helps to maintain customer relations by ensuring uniformly high

quality.

(v) it helps to avoid unnecessary machine adjustments so long as the

process is in a state of control.

(vi) Provides a basis for attainable specifications.

(vii) It serves as a means of determining, the capability of the manufacturing

process to turn out products with prescribed specifications. Thus Statistical
Quality Control tends to prevent production or purchase of bad items and
therefore, it is superior to inspection.

In the words of Frank M. Steadman

without quality control you, as a producer or purchaser, are

in the same position as the man who bets on a horse race
with one exception, the odds are not posted. SQC Will give
you the tools and your materials. It will tell you at what
level and with what variation you  are Operating and, more
important, it will tell you when your process, tools or
materials change from that level and range of variability-
possibly most important of all will be the change in outlook
on your purchases or production and the inspection of both.
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OBJECTIVES OF Statistical Quality Control

The main objective of statistical quality control (SQC) is
to achieve quality in production and service
organizations, through the use of adequate statistical
techniques. The following survey relates to
manufacturing rather than to the service industry, but
the principles of SQC can be successfully applied to either
1. To establish the desired quality standards which are acceptable to
the customers?

2. To discover flaws or variations in the raw materials and the

manufacturing processes in order to ensure smooth and uninterrupted
production.

3. To evaluate the methods and processes of production and suggest

further improvements in their functioning.

4. To study and determine the extent of quality deviation in a product

during the manufacturing process.

5. To analyse in detail the causes responsible for such deviation.

6. To undertake such steps which are helpful in achieving the desired

quality of the product.