Quality control

(a) Briefly explain how the quality improvement helps to grow a production or service organization.

What is quality? Quality is about meeting the needs and expectations of customers

1. Increase customer loyalty with that product or service organization

Customers come again and repeat purchases again

Customers recommend the product or service to others. Some customer after purchases if it has good quality he give good comments about it with his friend. It is big help to growing to business.

2. Can build up good and strong brand reputation for quality

if Any company has good brand reputation they can easily can increase them sells.

Example: - Sony Company has god brand reputation for quality than other electric equipment companies. Because they doing lot of quality improvements for them product.

3. Retailers want to stock the product

Retailers are going to make stock mean production company can make big sales. It helps growing them business. Because they can do lot of investment form them money.

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Quality control

4. Any product or service has done quality improvements they perceived to be better value for money. It may commend a best price and will become price increase. But customers purchase it because they think higher quality of that product.

Examples:-We can buy Benz car more than 20 million But we can buy Toyota car 5 millions .but some customs going to buy Benz car. Because they Benz product has better value for money and that brand also has higher value for money

5. quality improvement help to make profitable business.

Product or service has good quality improvements mean they have good market sale and market share and higher productivity/ efficiency and low production cost. That mean after the quality improvement processes any company can earn lot of profit. as

6. higher the job security ,higher the job satisfaction Now we know quality improvement help to make profitable business. The part of profit goes All the employees of that company. Increase them bonus and they have lot of benefits those things help increase to job satisfaction and job security.

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Quality control

(b) As a manufacture, how could you achieve a good quality product through its design and production phases

What is quality of design?

Measure of how will be designed in product/ service to achieve the required product

Product or service organization mainly follows two important quality concepts Quality of designs Quality of conformance to design

1. Quality of designs Product or service organization measure how will be designed in product or service to achieve the required product

How to achieve quality product though its design?

I. Normally designer collect data’s though the markets researches. Researches gave data’s about obtain customers needs and what available now in the market. Now designer can decide the best method. If any product service can full fill customers requirements they can achieve higher sell and can billed higher brand reputation.

II. Before decide final design designer have to consider man capacities of plant, technologies are available.

III. Now designer decide actual specifications. Following factors :-

2. Quality of conformance to designMeasures in what extent the product/service match with the design and customer actually receives should confirm to the design. Some time can depend on number of variables

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1. Aesthetic characteristics 2. Performance characteristics 3. Obligatory regulations characteristics4. environment factors important

Final inspection Final and fixed intermediate Final and faxable intermittent inspection

4. Patrol inspection 5. Centralized inspection

Check 100%

Check only samples

Quality control

02. (a) Explain why collective application of quality inspection, quality control and quality assurance need to ensure a good quality product or service

Quality inspection

Inspection methods

Advantages and purpose of Quality inspection:-

To detect poor quality products and separate them from acceptable quality products and scrap, rework and sell them as second quality

In this Quality inspection process we can identified defect.

Don’t give any feed back to production process. After the inspected get a decision made whether accept or reject

Disadvantages:-

1. Late detection of defects,2. Higher cost of defective work 3. poor access to production supervision 4. scrap quantity higher

Due this disadvantages Quality inspection not enough to maintain higher quality of the product.

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Quality control

Quality control

Main part of quality control:-

Is quality inspection where the product was checked to ensure that it meet the customer requirements

Quality control a process for maintain standards and not for creating standards

Not like inspection gave the feed back to process to control / adjusts to minimize defects in future production .this is main advantage of quality control.

Other advantages:-

to increase the profit of business to enable to complete successfully to enable to reduce cost of production

Disadvantages:-

Defect detect after the manufacturing Higher manufacturing cost Needing more man power to maintain quality

Quality assurance

Improving and stabilizing production and associated process to avoid or at least minimize. Issues that led to the defects in the first place (before begin the production)

Related to systems and not to a product as in quality control

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Before production Make quality manuals Systems certification

Process of production Maintain quality standards In process Inspection

Final products Final Inspection Identify defects

Give feed back

Higher quality products Quality inspectionQuality control Quality assurance

Quality control

Quality assurance focus on

Quality manuals Systems certification Quality cost Documentation

Now we can understand quality inspection or quality control or quality assurance not enough to maintain to quality of product we want collective application of this three concepts. This collective application has lot of advantages of inspection, quality control and quality assurance

process chart of higher quality process

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Quality control

(b) What is ISO 9000 standard ? explain why ISO 9000 certification essential to obtain for any production or service organization

The ISO 9000 family of standards represents an international consensus on good quality

management practices. It consists of standards and guidelines relating to quality

management systems and related supporting standard

ISO 9000 is a standard for a quality SYSTEMS not for product

Why ISO 9000 certification essential to obtain for any production or service

organization

1. increase customer satisfaction and retention

if any products has ISO 9000.that mean that products product by under the ISO

standards. Customers can purchases it without any afraid.

2. Create a more efficient, efficientive oparations

3. Enhance marketing

4. Improve employee motivation, awareness and morale

5. Promote internal trade

6. Increase profite

7. Reduce wastage and increase productivity

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Cost of control (cost of conformance) cost of failure of control

Prevention costIncludes the cost of any action taken to investing quality defectsProcess controltraining quality personnel design review

Apprasist costCost needed to discover the quality level during production 1.Inspection R.M2. In process inspection 3. Quality audits

Internal failure cost Cost incur prior to the delivery to customer 1.Scrap 2. Rework and repair 3.cost of wastage time

Quality control

03.

(a) What do you understand by “quality cost” ?

Total costs incur to ensure that product/ service provides conformation to the customer requirement.

Quality cost =Inspection cost +testing cost +quality standard maintain cost+ process control cost+ defect rejection costs This all costs go to quality costs. but we can category this cost under this factors

Quality cost categories

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External failure cost

Incur after transfer of ownership to the customer

1.Replacement of defect products2.complains

Quality control

(b) A garment manufacturer has collected the following quality cost data. assign the to thefour cost categories and present your finding as a percentage of total the cost

type of quality cost cost in rupees PC AC IF EF

scrap 75000     75000  

rework and repair 80000     80000  

final inspection 65000   65000    

returned garments 55000       55000

in-process inspection 35000   35000    

raw matrials inspection 25000   25000    

retesting 30000     30000  

quality planing 20000 20000      

quality systems audite 20000   20000    

quality improvement programme 55000 55000      

quality training 15000 15000      

total 475000 90000 145000 185000 55000

perecentage   18.9473684 30.5263158 38.9473684 11.578947

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Quality control

4. Quality control department following defect at various sections of a garment factory

1. In pattern making section : some pattern of size 12 ,14 and 18 mixed Resent= Didn’t pest or didn’t named part name pattern sizes like that information

To avoid =Pest label to each parts include this details (part name ,pattern size )

2. In marker making : marker width is larger than average fabric roll width Resent = didn’t measure fabric average width before make maker

To avoid = Must check the fabric width before make marker

3. Spreading section: larger cut garment panels than actual size

Resent = fabric spread in low tension

To avoid= Maintain proper and correct tension in spreading

4. Sewing section: skip stitches found with top stitching of shit pockets

Resent=due to hook irregular fails to pick up the loop tread

To avoid= use correct hook points without any damage ,Feed machine in proper thread loop formation

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