Module 6 – Quality Control in
Manufacturing
By
Engr. Dr. Patrick U. Akpan
[Link]@[Link] +2348102475639
Department of Mechatronic Engineering, University of Nigeria
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Module Objectives
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Lecture Outline
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Quality Control - Definition
Quality Control (QC) is a
systematic process that
ensures a product or service
meets specified
requirements by identifying
and rectifying any issues that
may affect quality. In
manufacturing, QC helps
maintain high standards and
ensures product consistency.
Importance of Quality Control
• the production of high-
quality,
QC is crucial • defect-free products that
in meet customer expectations
manufacturing and regulatory requirements.
as it ensures : • Rework is reduced
• Waste is minimized
• Efficiency is Improved
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Objectives of Quality Control
Consistency • Achieving uniformity in product dimensions,
and Reliability: functionality, and durability.
Customer • Meeting or exceeding customer expectations
Requirements: in terms of quality and functionality.
Regulatory • Ensuring products comply with safety and
Compliance: industry standards.
Waste • Minimizing errors, scrap, and rework to
Reduction: optimize production costs and efficiency.
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Types of Quality Control
Inspection-based QC
Statistical Process Control (SPC)
Total Quality Management (TQM)
Six Sigma
ISO Standards
1. Inspection based
Inspection-based QC
- Traditional method where inspectors check products for defects. Suitable
for simpler processes but may miss some issues in complex systems. It
involves 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.
Types of Quality Inspection
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Requirements for Quality Inspection
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Statistical Process Control
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2. Statistical Process Control
Statistical Process Control (SPC)
Statistical process control (SPC) monitors manufacturing
processes with technology that measures and controls quality.
SPC triggers various machines and instruments to provide quality
data from product measurements and process readings.
Once collected, the data is evaluated and monitored to control
that process.
Statistical Process Control (SPC)
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Control Charts for Process
Variables and Attributes
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Control Charts
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Control Charts for Variables - X bar
Process is stable
within the UCL
and LCL
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Control Charts for Attributes – P Chart
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P-Chart Example
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Relevant Formulars
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P-Chart Worked - Example
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C - Chart
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C - Chart
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Process Capability Analysis
A process capability study uses data from a sample to PREDICT the
ability of a manufacturing process to produce parts conforming to
specifications. This prediction enables us to "qualify" a new
manufacturing process as being fit for use in production.
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Production Characteristics Curve
The quality of a manufacturing process is
measured by the output of product quality
characteristics. If product
characteristics/specifications conform to
engineering/customer requirements, then the
process is considered stable/capable and
performing well as per set standards.
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Process Capability Analysis
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Improving the Manufacturing Processes
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Process Capability Indices: Cp and Ck
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CpK
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Equations for Process Capability
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Total Quality Management
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3. Total Quality Management
Total Quality Management
4. Six Sigma
A data-driven approach focused on defect reduction and improve
processed. Six Sigma projects follow a structured DMAIC (Define,
Measure, Analyze, Improve, Control) process.
5. ISO Standards
❖ ISO 9001 is the most widely recognized standard for quality management systems. It
provides guidelines for creating efficient quality management practices.
Quality Control Processes
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Quality Control Process
Setting Standards:
• Define quality criteria for materials,
processes, and products.
Identifying Key Quality • Determine critical product features
Characteristics (KQCs): that impact customer satisfaction.
Measuring • Use quality metrics to assess
Performance: adherence to standards.
Monitoring and • Implement real-time monitoring
Improvement: systems for ongoing improvement.
Quality Control Tools and
Techniques
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Quality Control Tools – Check Sheets
Quality Control Tools and Techniques
Check Sheets: • Simple data collection tool.
Cause-and-effect • Identifies possible causes of a quality issue.
Diagram (Fishbone):
• Helps focus on the most critical issues, based on the
Pareto Analysis: 80/20 rule.
Control Charts: • Track process stability over time.
Histograms: • Visualize the distribution of data.
Scatter Diagrams: • Analyze relationships between two variables.
Flowcharts: • Map out process steps to understand workflow.
Quality Control Tools – Fishbone Diagram -
Cause and Effect Diagram
❖ A cause and effect diagram, also known as an Ishikawa or “fishbone” diagram, is a
graphic tool used to explore and display the possible causes of a certain effect.
Use the classic fishbone diagram when causes group naturally under the
categories of Materials, Methods, Equipment, Environment, and People.
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Example of use of Fishbone Diagram
Types of Attribute Control Chart
Type What is Counted Sample Size
P-chart Defective items Varies
Np-chart Defective items Constant
C-chart Defects on an item Constant
U-chart Defects on an item Varies
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Quality Control Tools - Pareto Analysis
▪ Pareto analysis seeks to discover from an analysis of defect reports or customer complaints which "vital few"
causes are responsible for most of the reported problems.
▪ The old adage states that 80% of reported problems can usually be traced to 20% of the various underlying
causes.
Vital Many
Insignificant many
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Example – Pareto Analysis
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Scatter Diagrams
scatter diagram is used to examine the relationship between both the axes (X and Y) with one
variable. In the graph, if the variables are correlated, then the point drops along a curve or line. A
scatter diagram or scatter plot gives an idea of the nature of relationship.
Quality Management Systems
•ISO 9001: A globally recognized standard for quality
management that provides guidelines for establishing a
QMS.
ISO 9001 and •Implementation: Steps to achieve ISO 9001 certification,
Other Standards including documentation, process control, and continuous
improvement.
•Figure: Flowchart showing the steps to implement ISO
9001 in a manufacturing organization.
•Steps: Define quality objectives, document processes,
Implementation train employees, and establish a corrective action
system.
and •Continuous Improvement: Use feedback loops, audits,
Maintenance of and corrective actions to continually improve QMS.
•Case Study: Example of a company implementing ISO
QMS 9001 to improve product quality and customer
satisfaction.
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