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QA/QC -203 Unit 8: Pg.: Fundamentals of Quality Control 1 34.

Objectives U 8- Fundamentals of Quality Control  Understand the fundamental concepts of quality control and types of quality control .  Identify the steps in quality control , objectives and benefits of quality control .  Understand the fundamental concepts of quality control principles and process.  Identify the steps in quality control principles and process.  Learn about the quality control cycle , quality control measures and ways to improve quality control.  Understand the difference between Quality Control , Quality Assurance , Total Quality Management..

 The process through which the standards are established and met with standards is called control. This process consists of observing our activity performance, comparing the performance with some standard and then taking action if the observed performance is significantly too different from the standards. U 8 - Fundamentals of Quality Control Control.

 The control process involves a universal sequence of steps as follows: 1. Choose the control object 2. Choose a unit of measure 3. Set the standard value 4. Choose a sensing device which can measure 5. Measure actual performance 6. Interpret the difference between actual and standard 7. Taking action. U 8 - Fundamentals of Quality Control Control.

U 8 - Fundamentals of Quality Control Quality Control  Quality Control (QC) may be defined as a system that is used to maintain a desired level of quality in a Construction Projects . It is a systematic control of various factors that affect the quality of the Construction Projects . It depends on materials, tools, machines, type of Labour, working conditions  QC is a broad term, it involves inspection at particular stage but mere inspection does not mean QC. As opposed to inspection, in quality control activity emphasis is placed on the quality future production. Quality control aims at prevention of defects at the source, relies on effective feedback system and corrective action procedure. Quality control uses inspection as a valuable tool.

U 8 - Fundamentals of Quality Control.

U 8 - Fundamentals of Quality Control Types of Quality Control  QC is not a function of any single department or a person. It is the primary responsibility of any supervisor to turn out work of acceptable quality. Quality control can be divided into three main sub- areas, those are: 1. Off-line quality control: Its procedure deal with measures to select and choose controllable product and process parameters in such a way that the deviation between the product or process output and the standard will be minimized. Much of this task is accomplished through product and process design. Example: Taguchi method, principles of experimental design etc..

2. Statistical process control: SPC involves comparing the output of a process or a service with a standard and taking remedial actions in case of a discrepancy between the two. It also involves determining whether a process can produce a product that meets desired specification or requirements. On-line SPC means that information is gathered about the product, process, or service while it is functional. The corrective action is taken in that operational phase. This is real-time basis. 3. Acceptance sampling plans: A plan that determines the number of items to sample and the acceptance criteria of the lot, based on meeting certain stipulated conditions (such as the risk of rejecting a product lot or accepting a bad lot) is known as an acceptance sampling plan. Types of Quality Control U 8 - Fundamentals of Quality Control.

U 8- Fundamentals of Quality Control  Objectives of quality control: 1. To improve the companies income by making the production more acceptable to the customers, i.e., by providing long life, greater usefulness, maintainability etc. 2. To reduce companies cost through reduction of losses due to defects. 3. To achieve interchangeability of manufacture in large scale production. 4. To produce optimal quality at reduced price. Objectives of Quality Control.

 Objectives of quality control: 5. To ensure satisfaction of Client with Constriction Projects or high quality level, to build Client goodwill, confidence and reputation of Contractor . 6. To make inspection prompt to ensure quality control. 7. To check the variation during Construction Projects .The broad areas of application of quality control are incoming material control, process control and Construction control Objectives of Quality Control U 8- Fundamentals of Quality Control.

U 8- Fundamentals of Quality Control Benefits of Quality Control 1. Improving the quality of construction projects . 2. Increasing the productivity of construction processes, commercial business, corporations. 3. Reducing construction and corporate costs. 4. Determining and improving the marketability of construction . 5. Reducing consumer prices of construction . 6. Improving and/or assuring on time deliveries and availability. 7. Assisting in the management of an construction project.

Principles of quality control 1. Formulate quality policy. 2. Set the standards or specifications on the basis of customer’s preference, cost and profit. 3. Select inspection plan and set up procedure for checking. 4. Detect deviations from set standards of specifications. 5. Take corrective actions or necessary changes to achieve standards Quality Control Principles U 8- Fundamentals of Quality Control.

Principles of quality control 5. Decide on salvage method i.e., to decide how the defective parts are disposed of, entire scrap or rework. 6. Coordination of quality problems. 7. Developing quality consciousness both within and outside the organization. 8. Developing procedures for good vendor-vendee relations. Quality Control Principles U 8- Fundamentals of Quality Control.

Quality Control Principles U 8- Fundamentals of Quality Control.

1 – Product Design Analysis Step 1: Collaboration between Design and Production Teams Establish a collaborative approach where the design and production teams work closely from the initial stages. Step 2: Design for Manufacturability (DFM) Assessment Integrate DFM principles to ensure that the product is not only innovative but also manufactural with high quality. Quality Control Process U 8- Fundamentals of Quality Control.

2 – Raw Material Inspection Step 1: Establish Supplier Quality Standards Clearly define quality standards for raw materials in collaboration with suppliers. Step 2: Regular Supplier Audits Conduct regular audits to ensure suppliers adhere to established quality standards. Quality Control Process U 8- Fundamentals of Quality Control.

3 – In-Process Quality Control Step 1: Define Critical Control Points (CCPs) Identify key stages in the production process where quality control interventions are critical. Step 2: Real-time Monitoring Implement real-time monitoring using sensors and automation to detect deviations from quality standards promptly. Quality Control Process U 8- Fundamentals of Quality Control.

4 – Finished Product Inspection Step 1: Random Sampling Techniques Develop a robust random sampling strategy for finished products to ensure representative quality checks. Step 2: Comprehensive Testing Protocols Implement comprehensive testing protocols, including performance, durability, and safety tests. Quality Control Process U 8- Fundamentals of Quality Control.

5 – Quality Audits Step 1: Schedule Regular Audits Establish a schedule for internal and external audits to evaluate the overall effectiveness of quality control measures Step 2: Corrective Action Plans Develop corrective action plans based on audit findings to address any identified weaknesses. U 8- Fundamentals of Quality Control Quality Control Process.

6. Conduct a Comprehensive Quality Assessment Step 1: Initial Quality Baseline Evaluate the current state of quality within the organization to establish a baseline. Step 2: Gap Analysis Conduct a gap analysis to identify areas where existing practices fall short of desired quality standards. U 8- Fundamentals of Quality Control Quality Control Process.

7.Invest in Technology and Automation Step 1: Technology Assessment Assess the technological needs for quality control and invest in state-of-the-art tools and automation. Step 2: Integration with Existing Systems Ensure seamless integration of new technologies with existing production systems. U 8- Fundamentals of Quality Control Quality Control Process.

8. Continuous Monitoring and Improvement Step 1: Establish Key Performance Indicators (KPIs) Define KPIs that align with quality control objectives. Step 2: Regular Performance Reviews Conduct regular reviews using KPIs to monitor the effectiveness of quality control measures. U 8- Fundamentals of Quality Control Quality Control Process.

9.Engage Employees in Quality Improvement Initiatives Step 1: Employee Feedback Mechanism Establish channels for employees to provide feedback on quality-related issues. Step 2: Recognition and Rewards Implement a system for recognizing and rewarding employees who contribute to quality improvement. U 8- Fundamentals of Quality Control Quality Control Process.

10.Regularly Update Quality Control Measures Step 1: Periodic Review of Measures Conduct regular reviews of existing quality control measures. Step 2: Adaptation to Industry Changes Stay abreast of industry advancements and adjust quality control measures accordingly. Quality Control Process U 8- Fundamentals of Quality Control.

11.Employee Training and Skill Development Step 1: Training Needs Analysis Identify specific skills and knowledge gaps within the workforce. Step 2: Customized Training Programs Develop tailored training programs focusing on quality control measures and the use of new technologies. U 8- Fundamentals of Quality Control Quality Control Process.

12.Establish Clear Standard Operating Procedures (SOPs) Step 1: SOP Development Create comprehensive SOPs for every stage of the production process. Step 2: Training on SOPs Ensure that all employees are trained on and understand the SOPs relevant to their roles. U 8- Fundamentals of Quality Control Quality Control Process.

13.Implement a Closed-Loop Feedback System Step 1: Real-time Data Capture Implement systems to capture real-time data from various stages of production. Step 2: Feedback Analysis and Action Analyze the data to provide immediate feedback to relevant teams and implement corrective actions swiftly. U 8- Fundamentals of Quality Control Quality Control Process.

14.Collaborate with External Quality Standards Organizations Step 1: Identify Relevant Standards Identify and align with external quality standards relevant to the industry. Step 2: Certification Process Initiate the certification process to demonstrate adherence to industry-recognized quality standards. U 8- Fundamentals of Quality Control Quality Control Process.

U 8- Fundamentals of Quality Control Quality Control Cycle.

U 8- Fundamentals of Quality Control Quality Control Measures.

U 8- Fundamentals of Quality Control Ways to Improve Quality Control.

U 8- Fundamentals of Quality Control Difference Between Quality Control ,Quality Assurance and Total Quality Management.

U 8- Fundamentals of Quality Control  Quality Control (QC) may be defined as a system that is used to maintain a desired level of quality in a Construction Projects Summary  Quality control can be divided into three main sub-areas, those are: (Off-line quality control Statistical process control, Acceptance sampling plans).  The objectives of quality are : improve the companies income by making the production more acceptable to the customers, providing long life, greater usefulness, maintainability, to reduce companies cost through reduction of losses due to defects, produce optimal quality at reduced price..

 Benefits of Quality Control are : Improving the quality of construction projects ,Increasing the productivity of construction processes, commercial business, corporations, Reducing construction and corporate costs, Determining and improving the marketability of construction, Reducing consumer prices of construction, Improving and/or assuring on time deliveries and availability, Assisting in the management of an construction project Summary U 8- Fundamentals of Quality Control.