: Purpose of Inspection & Quality control, Difference between QC & QA,

Total quality Management(TQM), 7 QC tools, Overview on Statistical

process control (SPC)& Statistical Quality Control(SQC)- Control Charts &
acceptance Sampling, Sampling Plan "OC curve, AQL, AOQL & LTPD,
"introduction to six sigma, Kaizen
What is Quality ?
In operations management, quality is the degree to which a product or service meets or
exceeds customer expectations. It's a measure of how well a product performs and satisfies
customer needs.
Quality is defined by the degree of customer satisfaction with a product's
characteristics and features. Obviously, the fitness for use of the product
is fitness for use as the product was intended
Purpose of Inspection & Quality control
The purpose of inspection and quality control is to ensure that products meet or exceed customer expectations
and comply with legal regulations:
A quality inspection involves measuring, examining, testing, or gauging various
characteristics of a product and comparing those results with specified requirements to
determine whether there is a conformity. Quality Control (QC) is critical to build and deliver
products that meet or exceed customers' expectations
Safety
Inspections ensure that products are safe to use. For example, in automotive manufacturing, quality control
ensures that engines, drive trains, and other mechanical parts operate smoothly, efficiently, and safely.
Quality
Inspections ensure that products are of acceptable quality at all levels of production. This includes ensuring that
products meet the company's standards and any other legal regulations.
Customer satisfaction
Inspections help ensure that customers are always receiving products that meet their high standards. Happy
customers are more likely to come back and spread the word about your brand.
Cost
Inspections help to avoid costly rework and waste by finding defects early in the production process.
Supply chain
Inspections help to manage and preserve product quality throughout the supply chain. This includes ensuring
that every component and process adheres to pre-established quality standards.
TOTAL QUALITY MANAGEMENT
Total Quality Management (TQM) is a management approach that aims to achieve long-
term success by consistently delivering quality products and services to customers. TQM
involves the participation of all employees in improving the organization's processes,
products, services, and culture

Some key principles of TQM include:

Customer focus: Putting the customer at the center of the organization
Employee involvement: Ensuring that all employees are fully committed to the
organization
Continuous improvement: Constantly working to improve the organization's products,
services, and processes
Fact-based decision making: Making decisions based on facts
TQM typically involves a continuous improvement cycle called Plan, Do, Check, and Act
(PDCA). In this cycle, organizations:
• Plan for quality improvement
• Implement their plans
• Assess the results
• Take action based on the evaluation
One example of TQM in action is Toyota's Production System, also known as the Toyota
Way. This approach emphasizes employee empowerment, waste reduction, and continuous
improvement
Pros /Advantages of TQM
Delivers stronger, higher-quality products to customers

Results in lower company-wide costs

Minimizes waste throughout the entire production and sale process

Enables a company to become more adaptable

Cons/Disadvantages of TQM
May require substantial financial investment to convert to TQM practices

Often requires conversion to TQM practices over a long period of time

May be met with resistance to change

Requires company-wide buy-in to be successful

• The check sheet is used for collecting, recording, and analyzing the data.
• Data collection is an important activity in the problem-solving process as it provides
a basis for further action.
• Data may be numerical, observations and opinions, etc
 Fishbone diagram is also called as Cause and Effect diagram and Ishikawa diagram.
It helps to Identify all possible potential causes and select the real/best potential
cause which contributes to the problem/effect. The brainstorming technique is
used for potential cause identification.
 In a brainstorming session, all 4M or 6M factors are taken into consideration to
identify the potential causes. 4M or 6M factors are – Man, Machine, Method,
Material, Measurement, and Mother nature also called Environment.
A Histogram is a pictorial representation of a set of data, and the most commonly used
bar graph for showing frequency distributions of data/values. Histogram frequency
distribution chart is widely used in Six Sigma problem solving process.
 The Pareto chart helps to Narrow the problem area or prioritize the significant
problems for corrective measures. The pareto principle is based on the 80-20 rule. It
means that 80 percent of the problems/failures are caused by 20 percent of the few
major causes/factors which are often referred to as Vital Few.

 And the remaining 20 percent of the problems are caused by 80 percent of many
minor causes which are referred to as Trivial Many. Hence, it gives us information
about Vital few from Trivial many.
A control chart is also known as the SPC chart or Shewhart chart. It is a graphical
representation of the collected information/data and it helps to monitor the process
centering or process behavior against the specified/set control limits
A control chart is a very powerful tool to Investigate/disclose the source of Process
Variations present in the manufacturing processes. Tells when to take necessary action to
eliminate the Common or Random or Chance variations and Special causes of variations.

The control chart helps to measure and analyze the process capability and performance
(Cp and Cpk and Pp and Ppk) of the production process.
 A Scatter diagram is also known as Correlation Chart, Scatter Plot, and Scatter
Graph. A Scatter graph is used to find out the relationship between two variables.
In other words, it shows the relationship between two sets of numerical data.
Scatter graph shows a Positive or Negative correlation between two variables.
 Independent variable data and dependent Variable data are customarily plotted
along the horizontal X-axis and Vertical Y-axis respectively. Independent variable
is also called controlled parameters
A technique used to analyze and divide a universe of data into homogeneous groups is
called -Strata. Stratification tools are used when the data come from different sources
or conditions, such as data collected from different shifts, machines, people, days,
suppliers and population groups, etc.
A Process Flow Chart (PFC) is a diagram of the separate steps of a operations/process in
sequential order. PFC is also known as process flow diagram (PFD), and Process Map.
WHY DO WE NEED 7 QC TOOLS ?
We need Quality Tools for :

• Problem Solving – making decisions & judgments.

• For Process Measurement.
• For continual improvement in products, processes, and services.
• To improve Quality, Productivity, and Customer Satisfaction.

“95% of the problem is solved when clearly defined”

“95% of quality-related problems in the organization can be solved by using

seven fundamental quantitative tools.”
7QC Tools Benefits

The major benefits of QC tools are:

 To analyze and solve quality problems effectively.

 Improve product and process quality.
 Enhance customer satisfaction.
 Reduce cost due to poor quality.
 Helps in investigating the potential causes and real root cause of the problem for taking
effective countermeasures.
 Check sheet helps in data collection and recording for quality problem analysis.
 Identify and reduce the process variation using the SPC quality tool.
 The Pareto QC tool helps to narrow down the quality problem using the 80/20 rule.
 Helps in identifying the various sources of variations present in the process.
 Improve the employee’s analytical and problem-solving skills.
Statistical process control (SPC) is a systematic method for using statistical techniques to
monitor and regulate the quality of a production process
How does it work ?
SPC involves collecting and analyzing data in real-time at various stages of production. The
data is then plotted on a graph with control limits to identify any deviations or
abnormalities.
Benefits
SPC can help manufacturers:
• Reduce defects and waste
• Optimize production efficiency
• Maintain high-quality standards
• Improve equipment reliability
• Enhance customer satisfaction
Components
A statistical process control chart has three essential components:
Central line (CL): The average
Upper control line (UCL): The upper control unit
Lower control line (LCL): The lower control unit
Statistical quality control (SQC) is the use of statistical methods to monitor and
improve the quality of products and services. SQC is used in many industries, including
food, pharmaceuticals, and manufacturing.
SQC can be used to:
•Determine if a component is within acceptable limits
•SQC can determine if a production component is within acceptable statistical limits.
•Identify assignable causes of variation
•SQC can help identify assignable causes of variation in a production process.
•Monitor and maintain product quality
•SQC can be used to monitor and maintain product quality throughout the production
process, as a final quality check, or during random checks.
•Discover and correct problems
•SQC can help discover and correct problems before they become more serious.
Some methods used in SQC include:
•Acceptance sampling
•A method used to decide whether to accept or reject a group of items based on the
quality of a sample.
•Statistical process control
•A method that uses control charts to determine if a process should be adjusted or
continued to achieve the desired quality.
•Matrix data analysis chart