Growing a diversified global business

Quality Control Activities

ContentsContents

Quality Assurance – Goal/Implementation

Quality Control – Goal/Implementation

Quality Assurance Activities

Quality – an overview

Quality Improvement – Concept

Learning Objectives Learning Objectives

Quality Control

– Concept & Implementation

Quality Assurance

– Concept & Implementation

Quality Improvement - Concept

QA&QC Activities in Manufacturing QA&QC Activities in Manufacturing Quality Assurance

Implementation of QMS.

Control, update and revision of QMS documents .

Conduct internal Audit and coordinates with ISO certified body for certification.

Coordinate with client for external / third party audits

Maintain and control the Manual and SOP/MS/Written Practices.

Control and monitoring of NCR’s / CARs.

Second party audit of vendors and subcontractors.

QA&QC Activities in Manufacturing QA&QC Activities in Manufacturing Quality Assurance

Preparation of documentation and Quality related procedures

Conducts Quality Review Meeting.

Review and analyze customer complaints and other re-occurring problems in the process.

QA&QC Activities in Manufacturing QA&QC Activities in Manufacturing Quality Control

To carry out stage and final Inspections & preparation of associated reports.

Client and Customer cordination and handling.

Material inspection during receiving and before issuance to fabrication.

Welding control and monitoring of repair rates

Supervision of non-destructive testing.

QA&QC Activities in Manufacturing QA&QC Activities in Manufacturing Inspections

Incoming goods inspection.

Marking & layout inspection.

Fit up inspection .

Weld visual inspection.

NDT Review ,Witness & Clearance.

Hydro test witness

Surface preparation & painting inspection

Packing & Shipment inspection

QA&QC - Improvement areas QA&QC - Improvement areas Concepts????

Thinking that Quality is expensive; it lowers productivity

Thinking that Quality is intangible; it cannot be managed

Thinking that Poor quality means poor workers

Thinking that Quality is the responsibility of quality

department only

Thinking that Quality is a Department

Thinking that Quality is role specific

Thinking that Quality is someone else’s job

Thinking that Quality is not a major issue; it has little

impact on the company

QA&QC - Improvement areas QA&QC - Improvement areas Where should we go from here?

We must go back to the past………. Back to the basics

Basics …………..

Which Quality leaders have been advocating from many years

Overview Overview

Overview Overview

Overview Overview

DESCON

Bevel, Fit-up, Alignment etc

Welding visual inspection

NDE

Spool Erection & Welding

Pressure Testing

Quality Control Quality Control Concept

Process of making sure that products or services are made to consistently high standards

It is product oriented

It coordinates the links between the following activities:

Specifications of what is required.

Components, elements of the product

Inspection of the product to determine conformance to customer specification.

Quality Control Quality Control

Quality Control Quality Control

Quality Control Quality Control

Traditional QC

Inspection of products and services takes place during and at the end of the manufacturing process

Problems: Not a value-added activity

Too late

Costly

Human factor in inspections

Quality Control Quality Control

Example – Pressure Vessel Production

Raw material

Final Product

Quality Control, only, is not enough Inspections for defects – too late

Quality Control Quality Control

Quality Assurance Quality Assurance Concept

A set of activities designed to ensure that the development and maintenance process is adequate to ensure a system will meet its objectives.

A process of verifying or determining whether products or services meet or exceed customer expectations.

A process driven approach with specific steps to help define and attain goals.

Quality assurance defines the quality policy and in turn, how to follow the policies in better way to avoid any issues/defects thus saving time effort and money in the production of product but also providing the customer with exactly what they require.

Quality Assurance Quality Assurance

HOW SURE ARE YOU??” :: focus on the process involves, and make sure you do the right

thing.

To ensure that the products/services meet the customer’s requirements at the highest standard.

:: customer requirement/needs may change in time.

Determine if the steps/process implemented to produce the product/service are appropriate with the time and conditions.

Quality Assurance Quality Assurance

Internal audit / First party audit :: a systematic, independent and

documented process, conducted by members within the organization and obtain evidence and evaluate it to determine where requirements are fulfilled.

External audit / Second or Third party audit

:: similar to internal audit, but conducted by members not within the organization.

Quality Assurance Quality Assurance

:: PDCA analyzes existing conditions and methods used to provide the product or service to customer.

QC vs QA QC vs QA Quality control emphasizes testing and blocking the

release of defective products,

Quality assurance is about improving and stabilizing associated processes to avoid or at least minimize issues that led to the defects in the first place.

However, QA does not necessarily eliminate the need for QC: some product parameters are so critical that testing is still necessary just in case QA fails

Quality in an OrganizationQuality in an Organization

Overview Overview

Quality Improvement Quality Improvement

Keyword : IMPROVEMENT

The continuous study and improvement of a process, system, or organization

A continuous process that identifies problems, examines solutions to those problems, and regularly monitors the solution implemented for improvement.

Example in manufacturing / industry : reduce product failures or work related injuries.

Example in administration / service : increase efficiency or reducing re-work.

It is aimed at improvement - measuring where you are, and figuring out ways to make things better. It specifically attempts to create systems to prevent errors from happening.

QI activities can be very helpful in improving how things work. Trying to find where the “defect” in the system is, and figuring out new ways to do things can be challenging and fun. It’s a great opportunity to “think outside the box.”

Quality Improvement Quality Improvement

Five (05) crucial activities to Quality Improvement

Quality Improvement Quality Improvement

An example: FADEE Model

Quality Improvement Quality Improvement

Quality Improvement Quality Improvement

Ordinary Company QI* Company

Quality is expensive. Quality leads to lower costs.

Inspection is the key to quality.

Inspection is too late. Workers should produce defect-free goods, right at first time

Defects are caused by workers.

Most defects are caused by the system

Rewarding the best performers and punishing the worst will lead to greater productivity and creativity

Most variation is caused by the systems that judge, punish, destroy teamwork.

Profits are made by keeping revenue high and costs down.

Profits are generated by loyal customers.

Quality Improvement Quality Improvement

Quality Improvement Quality Improvement How can you make the difference?

Be a quality professional – Who is quality

professional?

Starting point for improvement - recognize the need

Be an agent for change in your organization

Show people how to prevent problems, not just

identify them

Promote quality’s image - Inside & outside

Constantly learn more about quality

Educate, train, and support those who do the work