Quality monitoring systems

• Checking for accuracy
• Checking for safety
• Checks carried out after manufacturing
• Check could be visual/automated/computerised
• Testing could be destructive/non-destructive
• Against the specification
• So that product meets expecations

Advantages	Disadvantages
Less faulty products being sold to customer High quality product - better reputation for company	Quality control can be expensive Can slow down rate of production Does not prevent the waste of resources when products are faulty Does not identify the issues, only that there is one

Applications: Casting parts, products, car engines

Inspection:

Used to check that manufactured products have been produced with a tolerance (e.g. +/- 5mm)

• 100% inspection - everything is inspected
• Normal sampling - test every 100^th product etc
• Reduced inspection - every 10,000^th product, used when the level of quality is 'sufficiently good'

Computer-aided inspection:

Uses a coordinate measuring machine (CMM) for dimensional measuring. Laser scanning machine are similar to CMM.

Testing/checks:

Measures the products performance

• Check material quality (destructive/non-destructive tests)
• Check function (does it work)
• Check the parts fit together
• Surface finish (burrs/scratches)
• Testing for sharp croners/edges
• Check casting quality (flaws/cracks etc)
• Check for correct assembly (missing components)
• Check threads are fully cut
• Check qualities of decals/printing/position

Reducing cost of testing:

• Only test sampling method
• Use of gauges (reduces delays)
• Limit destructive testing (less labour needed)

Non-destructive testing:

Where the product is tested until it shows signs of failure (cracking etc)

Destructive testing:

Where the product is tested until it is destroyed

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Quality assurance

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Used by the manufacturer to monitor the quality of the product from its design and development stage to its manufacture

• Applied at every stage of design and manufacture
• To make a product with no faults
• To ensure the product is fit for use
• External QA checks employed (ISO/BSI/CE)
• Quality of components monitored by quality control checks

Advantages

Disadvantages

Ensures product is not faulty Better customer satisfaction (high quality products) Costs are reduced because there is less wastage and reworking of faulty products as the product is checked at every stage It can help improve worker motivation as workers have more ownership and recognition for their work It can help break down 'us and them' barriers between workers and managers as it eliminates the feeling of being checked up on With all staff responsible for quality, this can help the firm gain marketing advantages arising from its consistent level of quality

Time consuming Costs a lot of money to train staff Time consuming to train staff Arguments between employees and QA employess

Applications: High quality products, construction, engines

Total quality management (TQM):

• Used to help achieve customer satisfaction by applying quality assurance procedures at every stage
• TQM is based on all members of an organisation participating in the continual improvement of processes, producers and services
• Re-engineering processes and systems to improve products and services
• Reducing loses due to wasteful practices

Advantages	Disadvantages
Make products right the first time Covers all aspects of the design and manufacturing (reduce waste) Reduces cost of wastage from faulty goods` Equipment is monitored to make sure it functions correctly Improved quality product improves reputation of business Staff receive more training Shorter production times	Increases cost in development of flawless product Employees can be resistant to changes Time consuming/slow process to introduce Testing/inspections can be expensive Cost of introduction may outweigh the savings made

Applications: Goods and services

ISO 9000:

• Defined as a set of internatioanl standards on quality management and quality assurance
• Helps company to effectively document the quality system elements needed to maintain an efficient quality system
• Not specific to one industry
• Helps to satify its customers

Seven points they look at:

Customer focus (existing needs/future customers)

Leadership (establish a vision and direction)

Engagement of people (use their skills properly/open discussion)

Process approach (deploy resources effectively/prioritise improvements)

Improvement (improve organisational performance/capabilities)

Evidence-based decision making (using data and analysis)

Relationship management (share expertise/resources/information)

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