MEASUREMENT AND

QUALITY CONTROL (ME361)

Conducted by
Dr. Md. Arafat Rahman
Assistant Professor
Dept. of Mechanical Engineering
CUET
 MEASUREMENT AND QUALITY CONTROL
(ME361)
3 credit, 3 periods/week
Theory
Introduction: Objective of quality control, measurement and instrumentation.
Measurement:
Basic principles of measurements, measuring and recording methods, instrument calibration;
measurement of displacement, pressure, temperature, heat-flux, flow, motion and vibration, force,
torque, strain, etc.; data acquisition, analysis and processing, sources of error in measurements,
error analysis.
Techniques for maintaining standards, allowances and tolerance. Types of tolerance, grades of
manufacturing accuracy, limits and fits, types of fits. Basic hole system and basic shaft system,
selective assembly and interchangeable manufacturing, limit gauges, Taylor's principle of limit
gauging. >>>>>>>> 17 Classes
Quality Control:
Statistics and Probability: Review of probability, distribution functions e.g. Binomial,
hypergeometric, poission, normal, exponential, Erlangian, Gamma and Weibull distribution
Quality Control: Objectives, quality and quality assurance, TQM; concepts and tools, statistical
quality control (SQC), concepts of control charts, control charts for variables and attributes e.g. X,
R, C , P etc. charts, drawing of control charts and selection of subgroups, acceptance sampling and
sequential sampling.
Quality Assurance Programs: ISO, SA standards, requirements and certification procedure
>>>>>>>>> 20 Classes
Quality: In simple words, quality means “ Fitness for Use”. Quality is the degree to
which a commodity meets the requirements of the customer at the start of its
life. (ISO 9000)

People have found many ways to define what is quality. Some of the most popular
definitions for quality are listed below. All of them are right, as they each contain a
key element of what quality means to users of products and services.

 A degree of excellence
 Conformance to requirements
 Totality of characteristics which act to satisfy a need
 Fitness for use
 Fitness for purpose
 Freedom from defects
 Delighting customers

Reliability comes from achieving quality standards. This means the level of
quality produces its equivalent reliability.

However, Quality of the products varies person to person.

 For example, one shirt can give all satisfaction to one
customer for its quality (color, fitting, texture etc) but
this shirt is not preferable to another customer for its
same qualities !!

Quality Control: In a word, controlling quality of a product by a suitable

reference is called quality control. Sometime, it is the process of sorting good
from bad.
Controlling Quality is interesting !!!!
 Benefits of Quality Control in Industry
 Improving the quality of products.
 Increasing the productivity of manufacturing processes.
 Reducing manufacturing and corporate costs.
 Determining and improving the marketability of products.
 Reducing consumer prices of products.
 Improving and/or assuring on-time deliveries and availability

The quality of a product can be evaluated in many ways referred to as

dimensions of quality. Therefore, it is important to differentiate among these
dimensions:
 Performance: Will the product do the intended job?
 Reliability: How often does the product fail?
 Durability: How long does the product last?
 Serviceability: How easy is it to repair the product?
 Aesthetics: What does the product look like?
 Features: What does the product do?
 Perceived quality: What is the reputation of the company or its product?
 Conformance to standards: Is the product made exactly as the designer
intended?
 Quality Control Process
Quality control is a process intended to ensure that product quality or performed
service adheres to a defined set of criteria or meets the requirements of the client.
Through the quality control process, the product quality will be maintained, and
the manufacturing defects will be examined and refined.

The quality control process is divided into three separate processes, which are IQC
(incoming quality control), IPQC (in-process quality control) and OQC (outgoing
quality control).
IQC - Incoming Quality Control
Incoming quality control is the process to inspect the raw and component materials
from suppliers upon arrival. When detective parts are found, you need to negotiate
with the supplier for return or exchange, and the final purpose is to make sure
your product quality will not be affected. Below is a sample.

Specific tasks of IQC include:

Perform approved vendor list check;
Evaluate supplier quality records;
Perform sampling of incoming materials
based on the standard;
Perform dimension, visual and functional
inspection of material samples;
Monitor quality control chart of inspected
properties and alert engineering staff of
significant deviations;
Continuously enhance the IQC process.
IPQC - In-process Quality Control
IPQC refers to the quality control during the assembly process. It is very important
because you can detect and handle the problem that occurs ahead of time.

Specific tasks of IPQC include:

 Perform inspections on assembled and in-
process materials according to standards;
 Conduct in-line automated and manual
inspections
 Apply first-article inspection after process
setup;
 Utilize statistical control techniques and
watch for significant deviations;
 Perform in-process audits to ensure
processes are up to standard, and to
identify factors needing improvement.
OQC - Outgoing Quality Control
OQA is the inspection of products before shipping. It's a crucial step in ensuring the
shipment is defect-free.

Specific tasks of OQA include:

Perform visual and functional inspection;
Verify first-article inspection;
Repeat approved vendor list check;
Apply sampling based on the standard;
Conduct reliability testing;
Submit failure analysis reports and alert
engineering staff.
Objectives of Quality Control
Following are the important objectives of quality control:
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 analyze in detail the causes responsible for such deviation.
6. To undertake such steps which are helpful in achieving the desired quality of the
product.
 Statistical Quality Control (SQC)
SQC is used to analyze the quality problems and solve them. Statistical quality
control refers to the use of statistical methods in the monitoring and maintaining
of the quality of products and services. All the tools of SQC are helpful in
evaluating the quality of services.

All the tools of SQC are helpful in evaluating

the quality of services. SQC uses different tools
to analyze quality problem.
1) Descriptive Statistics
2) Statistical Process Control (SPC)
3) Acceptance Sampling

Descriptive Statistics involves describing

quality characteristics and relationships.
SPC involves inspect random sample of
Figure: Nail manufacturing
output from process for characteristic.
Acceptance Sampling involve batch sampling
by inspection.
Objective of Statistical Quality Control
Quality Control is very important for a every company. Quality control includes
service quality given to customer, company management leadership, commitment of
management, continuous improvement, fast response, actions based on facts,
employee participation and a quality driven culture.

The main objectives of the quality control module are to control of material reception,
internal rejections, clients, claims, providers and evaluations of the same corrective
actions are related to their follow-up. These systems and methods guide all quality
activities. The development and use of performance indicators is linked, directly or
indirectly, to customer requirements and satisfaction, and to management.
Advantages of Statistical Quality Control (SQC)
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.
(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.
Total Quality Management
A cost effective system for integrating the continuous quality improvements of
people at all levels in an organization to deliver product services, which ensure
customer satisfaction. The concept of bringing a quality focus to every aspect of an
operation from raw materials received to accounting invoice accuracy. Company
wide quality management system involving all employees in activities aimed at
improvement of product quality, production process and services.

Objectives of TQM
Total Quality requires management practices to shift towards a new form. It
includes these components:

1. Customer needs, not production, are focus.

2. The system becomes more horizontal with everyone working towards a single
goal, to serve the customer better.
3. Every one is considered in decision-making.
4. Employee empowerment and responsibility replace rigid policies and
procedures.
5. Cooperation across function is frequent.
6. Team takes on some of the roles of departments.
7. Workers are cross-trained and their jobs are more flexible.
Principles of TQM
TQM can be defined as the management of initiatives and procedures that are
aimed at achieving the delivery of quality products and services. A number of key
principles can be identified in defining TQM, including:
Executive Management – Top management should act as the main driver for
TQM and create an environment that ensures its success.
Training – Employees should receive regular training on the methods and
concepts of quality.
Customer Focus – Improvements in quality should improve customer
satisfaction.
Decision Making – Quality decisions should be made based on measurements.
Methodology and Tools – Use of appropriate methodology and tools ensures
that non-conformance incidents are identified, measured and responded to
consistently.
Continuous Improvement – Companies should continuously work towards
improving manufacturing and quality procedures.
Company Culture – The culture of the company should aim at developing
employees ability to work together to improve quality.
Employee Involvement – Employees should be encouraged to be pro-active in
identifying and addressing quality related problems.
 Tools of TQM
Cause-and-effect diagram (also called Ishikawa or fishbone chart): Identifies
many possible causes for an effect or problem and sorts ideas into useful
categories.
Check sheet: A structured, prepared form for collecting and analyzing data; a
generic tool that can be adapted for a wide variety of purposes.
Control charts: Graphs used to study how a process changes over time.
Histogram: The most commonly used graph for showing frequency distributions,
or how often each different value in a set of data occurs.
Pareto chart: Shows on a bar graph which factors are more significant.
Scatter diagram: Graphs pairs of numerical data, one variable on each axis, to
look for a relationship.
Stratification: A technique that separates data gathered from a variety of sources
so that patterns can be seen (some lists replace “stratification” with “flowchart” or
“run chart”).

Plan-Do-Check-Act (PDCA) :
The Plan-Do-Check-Act style of management where each project or procedure is
planned according to needs and outcome, it is then tested, examined for efficiency
and effectiveness, and then acted upon if anything in the process needs to be
altered. This is a cyclical style to be iterated until the process is perfected. All of
these TQM tools can be easily created and examined by using various types of
computer software or by simply mapping them out on paper.
They can also be easily integrated into team meetings, organizational newsletters,
marketing reports, and for various other data analysis needs. Proper integration
and use of these tools will ultimately assist in processing data such as identifying
collecting policies, enhancing work flow such as mapping acquisition procedures,
ensuring client satisfaction by surveying their needs and analyzing them
accordingly, and creating an overall high level of quality in all areas of your
organization.
 Quality: Variable vs. Attribute
Variable: The quality characteristics which can be measured! E.g. length, weight,
surface finish, speed, Watt, resistance, etc. [QUANTATATIVE]
Attribute: The quality characteristics which can NOT be measured! E.g.: Good or bad

Quality Assurance: The maintenance of a desired level of quality in a service or product,

especially by means of attention to every stage of the process of delivery or production.

QC is used to verify the quality of the output;

QA is the process of managing for quality.
Quality Inspection
Process