Introduction to Quality Control in Manufacturing

QC or Quality control is a routine operation used by businesses to ensure the quality of their products. It requires the full potential of both employees and management. In addition, this is carried out by laying out benchmarks for the quality of the products and training the employees. Utilising certain pre-distinguished controls is an important aspect of exercising quality control in manufacturing. These controls enable the standardisation of productions. And helps to respond to issues related to quality. Assigning specific roles to each employee can limit the chances of committing errors in the production process. This ensures that each employee has adequate training for the task.

Why is it important to have quality control in the manufacturing industry?

• QC ensures the improvement and maintenance of product quality through a systematic process.

• Quality control uses testing units to determine if they achieve the required stipulations for the end product.

• QC is carried out in a company based on the industry or product, using various techniques for measuring quality.

• The food and beverage industry uses QC methods to ensure customers don't consume harmful products.

• QC creates safe procedures that enable the company to avoid selling damaged or deficient products to their customers.

Quality control uses testing units to determine if the end product is within the required specifications. Through testing, companies can determine corrective measures in the production process. Efficient quality control can help companies satisfy buyers' demands for good-quality items.

Quality testing and quality control in the manufacturing industry

Quality testing for manufacturing is a part of the production process level. As a result, employees usually start with raw material testing and end with the completed product test. Consequently, carrying out tests at different manufacturing points makes it easy to recognise where the issue is. Therefore, this enables them to exercise remedial measures to prevent those issues from repeating.

A company's QC or quality control for manufacturing policies depend on the industry or product. Quality control in manufacturing drugs and food accounts for if the product makes a consumer fall sick. In such operations, the company conducts microbiological and chemical tests on samples. Due to the influence of appearance on the consumer's perception, the company may present the product with the final package.

In the manufacturing of vehicles, quality control gives most attention to the fusing of parts. This ensures the smoothness and efficiency of engines by interacting with the components. In the electronics industry, testing involves using meters that let one measure electricity flow.

Quality Control Methods

There are various methods employed for the measurement of quality control. For instance, a QC chart depicts processes or sampled products concerning the targeted specifications. Further, charts that analyse specific attributes of products are called univariate charts. As a result, charts that measure variances in various product attributes are called multivariate charts.

X- Bar Chart

Products tested randomly for the specified quality or qualities are represented in an X Bar Chart format. In an X Bar Chart, the y-axis represents the degree of acceptable variance of a particular attribute(s). At the same time, the x-axis of an X Bar Chart represents the specimens tested. Analysis of the variance patterns in a QC chart can let one understand whether the defects are happening systematically or randomly.

Taguchi method

Another method of quality control in manufacturing is called the Taguchi. It involves highlighting product design, product development, and development and research duties. This enables the reduction of product failures and defects. In Taguchi, design has primary importance. This method emphasises the production process and instead attempts to eliminate the possibility of variances occurring. 

Hundred Percent Inspection Method

The Hundred Percent (100%) method of inspection is quality control for a manufacturing process requiring examining and assessing a particular product's entirety. And this method of QC is there to avoid errors in products. Usually, the 100 per cent inspection method is there to evaluate products made of valuable metals. Therefore, the 100 per cent inspection method involves software inventory analysis and study of the information on the production process.

The major difficulty in using this QC method is the need to examine each item intricately. This can prove to be expensive and can potentially render the item unusable or may even destabilise it. For instance, if one uses this technique to inspect organic strawberries, there is a chance of getting mushes or bruises. This would make the product unfit to be sold in the market.

How to improve quality control in manufacturing?

Quality control in manufacturing can be improved by using the following methods:

Inspectors of Quality Control in manufacturing (QC Inspectors)

Quality control in manufacturing inspectors keeps the defective products from getting into the customer's hands and saves the company's reputation. Suppose an inspector finds any issue with the item(s) after the tests. In that case, they can solve the problem themselves, bring the item(s) for repair, or mark it for rejection. If any issue is there in the items, the inspector informs supervisors and assists them in rectifying the problem.

Benefits of Quality Control in manufacturing benefits

Implementing QC inspectors ensures that the company sells the best quality products to its customers. Apart from that, quality control can positively influence employee performance. Therefore, it can inspire the personnel to produce high-quality merchandise leading to higher customer satisfaction.

QC protocols can help t company lower inspection costs and economically utilise their resources.

Examples

Six Sigma is a Quality Control methodology from Motorola. Motorola developed it in 1986. In addition, the method involves the reduction of defects through data-driven reviews. Further, the process emphasised cycle-time advancements and could limit the defects to 3.4 times in every million units. One developed the technique to decrease errors while documenting all the production procedures.

There were two major reasons for Motorola to introduce Six Stigma. Firstly, it was to compete with the strong rising competition from foreign companies, mainly the Japanese manufacturers. And secondly, it was to deal with the increasing number of customer complaints.

Introducing a new form of quality control for manufacturing dramatically improved Motorola's production and performance. In addition, after the first five years (1986-1991), the company met its targets of improvement in all areas of its business.

Six Sigma consists of a process involving five factors (DMAIC): definition, measurement, analysis, improvement, and control. As a result, this helps the company recognise and tackle the issues related to quality control. Consequently, local governments and tech giants such as Microsoft continue to use different forms of Six Sigma in the twenty-first century. 

Frequently asked questions about Quality Control.

What is the meaning of Quality control in manufacturing?

Quality control in manufacturing management maintains and improves (if required) the quality of the products. So, different methods exist to conduct quality control- creating benchmarks, testing products, and reviewing production processes. As a result, this is there to track measurable dissimilarities in a product's specifications.

Name the four primary QC methods?

There are various methods of QC. But, the four major quality control systems are the Hundred Percent Inspection Method, the Taguchi process, Six Sigma, and the X Bar Chart.

What is the importance of Quality control in manufacturing?

Quality control in manufacturing ensures that customers get only non-defective and good-quality products. In addition, companies that carry out proper quality control measures have personnel who are more focused on their task.

Food companies. While making food items, they keep an eye on the following.

• The ingredient conditions 

• Examining supplier records

• Hygiene and sanitation of the production facility

Differentiate between Quality Control and Quality Assurance?

Quality Assurance is about the manufacturing process of a product and its quality. At the same time, quality control concerns quality maintenance and how the enterprise supervises it.