Quality Control

•Quality and Process Improvement
Illustrate the
applications of
statistical
process control
Learning
when applied
Outcome 1:
in an industrial
environment to
improve
efficiency.
•Task :
Research and define the concept of quality in an industrial
environment, and identify why process improvement is critical
to achieving quality.
• Quality is the degree to which a product or service
meets customer requirements and expectations.
• In manufacturing, quality means producing goods free
of defects, within specified tolerances, and to standard
specifications.
• In service, quality means delivering services
consistently, timely, and as promised.
Task : Research and define the concept of
Statistical Process Control (SPC) and Cost of
Quality (CoQ)
• Statistical Process Control (SPC) is a quality control
methodology that uses statistical tools to monitor and control
processes.
•Statistical Process Control (SPC)
Definition of SPC:
SPC is a method that uses statistical tools, primarily control charts, to

monitor the stability and capability of a process over time. It helps in
identifying variations in the process that could affect product quality,
allowing companies to address the issues before defects are produced
•Importance of SPC in Industrial Environments
• SPC helps ensure processes remain stable by identifying and addressing variations.
Process Stability and • Processes under statistical control are predictable and allow for consistent product
Predictability: quality.
• Reducing process variation leads to fewer defects, minimizing waste and rework.
Reduced Variation: • By identifying assignable causes of variation (e.g., machine wear, material
inconsistency), corrective actions can be taken to improve the process.
Increased Efficiency:
SPC provides real-time feedback,

enabling quicker detection and
correction of process issues.
Maintaining process stability reduces
the time spent fixing quality-related
problems, leading to more efficient
use of resources.
Introduction to
Statistical Process
Control (SPC)
• Definition: SPC involves
checking a product or service
during its creation to identify
and rectify potential
problems.
• In simple phrase checking
the health of the process
• Walter Shoehart developed
SPC at the Bell telephone
companies in 1920s
• Example Applications:
• Airports: Sampling customer satisfaction regarding restaurant
cleanliness.
• Car Manufacturers: Periodic checks on door panel conformity to
ensure machinery is performing correctly.
The Seven Basic Quality Tools are essential for quality
management and process improvement. They provide
systematic methods for identifying, analyzing, and solving
quality issues, leading to better decision-making and enhanced
process control.
Kaoru Ishikawa – as much as 95% of all quality related

problems in the factory can be solved with seven fundamental
quantitative tools.
1. Pareto Chart
Description:
• A Pareto chart is a bar graph that represents the
frequency or impact of problems. The bars are
arranged in descending order of height from left
to right, with the tallest bars indicating the most
significant factors.
Usage:
• Helps identify the most significant factors in a
dataset, often following the Pareto principle
(80/20 rule), where 80% of problems are often
due to 20% of causes.
Example:
• Used in defect analysis to prioritize issues. For
instance, in a manufacturing process, a Pareto
chart can show that most defects are due to a
few specific causes.
•2. Cause-and-Effect Diagram (Ishikawa or Fishbone Diagram)
•Description:
• A diagram that identifies many possible causes for an effect or
problem. It resembles a fishbone, with the main problem at the head
and various causes branching off from the spine.
•Usage:
• Helps teams brainstorm and sort ideas into useful categories, such as
People, Methods, Machines, Materials, Measurements, and
Environment.
•Example:
• Used in root cause analysis to identify the underlying causes of
defects or quality issues in a production process.
•3. Check Sheet
•Description:
• A structured, prepared form for collecting and analyzing data. It is
designed to be easy to use and interpret.
•Usage:
• Effective for data gathering and analysis, ensuring consistent data
collection.
•Example:
• Used in defect or failure logging to record the frequency of specific
problems during a production shift.
•4. Control Chart
•Description:
• A graph used to study how a process changes over time. It displays
data points plotted in time order and includes a central line (mean),
an upper control limit, and a lower control limit.
•Usage:
• Helps in monitoring process variability and stability by showing
whether a process is in control or out of control.
•Example:
• Used in process control to monitor the quality of a manufacturing
process, ensuring that variations are within acceptable limits
•The control limits are + or – standard deviation from the centre line
•The dats for the process which we are plotting is within the control limits ,
then the process is in control
•Control Charts in SPC
• Purpose: Not only for single sample checks but to monitor quality over time.
• Functionality:
• Control charts help determine if a process is performing correctly or if it is
"out of control".
• Early detection of problems allows for corrective actions before significant
issues arise.
• Example:
• Charting the percentage of dissatisfied restaurant customers over time.
• A rising trend in dissatisfaction indicates a need for management
intervention.
Types of Quality Measures
• Attribute Measures: Qualitative data such as customer
satisfaction (e.g., satisfied or not).
• Variable Measures: Quantitative data such as weight,
dimensions, etc.
•Importance of Control Charts
• Trend Analysis:
• Identifying worsening trends to investigate underlying issues.
• Identifying improving trends to understand and replicate successful
processes.
• Management Insights:
• Sharing successful practices across the organization.
•Potentially stopping processes that improve quality but add unnecessary
expense
•5. Histogram
•Description:
• A bar graph that shows the frequency distribution of a dataset. Each
bar represents the frequency of data points within a specified range.
It differs from a bar graph which relates 2 variables.
•Usage:
• Displays the shape and spread of continuous sample data, helping
to understand the distribution pattern.
•Example:
• Used in distribution analysis to identify patterns, such as whether
data follows a normal distribution.
•Understanding Process Variation with Histograms
• Process Stability:
• When no exceptional factors influence the process, variations will
show a predictable pattern.
• Histogram Development:
• Initial measurements form a rough histogram.
• Over time, more data smooth out the histogram into a normal
distribution.
•6. Scatter Diagram
•Description:
• A graph that shows the relationship between two variables. Each
point on the graph represents an observation.
•Usage:
• Identifies potential relationships or correlations between variables,
helping to understand how one variable affects another.
•Example:
• Used in correlation studies to determine if there is a relationship
between two factors, such as temperature and product yield
•7. Flowchart (Process Diagram)
•Description:
• A graphical representation of a process, showing the sequence of
steps involved. It uses symbols to denote different types of actions or
decisions.
•Usage:
• Helps to understand and improve processes by providing a visual
overview, identifying inefficiencies, and areas for improvement.
•Example:
• Used in process mapping and redesign to visualize the steps in a
customer service process, identifying bottlenecks and areas for
improvement.

Quality Control

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•Quality and Process Improvement

SPC is a method that uses statistical tools, primarily control charts, to

SPC provides real-time feedback,

Kaoru Ishikawa – as much as 95% of all quality related

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