The cost of quality is very important to a Total Quality
Control program.
It is a factor for determining product cost as well as a measure to determinethe effectiveness of a Quality Control organization.
We will not dwell on theanalysis of quality costs, but we should be aware of some of the contributing factors.
Three general classifications of quality costs are:
1.
Failure Costs 2.
Prevention Costs 3.
Appraisal Costs The failure costs are associated with scrap, rework, and customercomplaints and rejections.
Included in appraisal costs are the salaries andcompensations to Quality Control and inspection personnel who are directlyresponsible for the inspection function, as well as cost of inspection andtesting equipment.
Prevention costs should include the salaries paid to personnel engaged inquality planning, quality training and developing quality inspection equipment.
In a well planned organization, the amount of money spent for prevention ofdefects and appraisal of the product should be approximately equal to the costof scrap, rework, and rejections.
This serves as a "rule of thumb" to determineif we are spending money properly to appraise the product to prevent scrap andrework.
Usually money spent on prevention and appraisal will not only reducefailure costs, but it will reduce the total costs as well.
Dr.
W.
EdwardsDemming suggests that the elimination of scrap and rework is one of the mostprofitable areas in which to increase productivity.
It costs the same toproduce a piece of scrap as it does to produce a good part.
Money and timespent in rework adds to the cost of the product without increasing production.
BENEFITS OF QUALITY
CONTROL OBJECTIVES OF QUALITY
CONTROL The most important objective of Quality Control is to assure good qualitymaterial to the customer.
Another objective is to obtain the desired quality ata minimum cost.
A third objective is to provide factual information relative toquality upon which the proper persons may base decisions.
We may call this"quality feedback information".
A good feedback system should include scrap andrework reports, machine and process studies, process capabilities, and a systemsand product audit report.
PRODUCT IMPROVEMENT The direct responsibility of producing good quality remains with themanufacturing departments.
If quality is not good, Quality Control shouldcollect data, analyze it, and present the facts to manufacturing and engineeringfor corrective action.
Many times a good study can detect the causes thatcontribute to a faulty process.
Since this requires teamwork on the part of Quality Control and Manufacturing, it is vital that both areas UNDERSTAND THE TECHNIQUES of statistical control.
A good corrective action program willimprove product quality and ultimately increase sales and profits.
QUALITY
-MINDEDNESS The proper use of control charts provide manufacturing personnel withinformation for product improvement.
The machine operator takes pride in doinga good job.
There is a significant psychological effect in the use of controlcharts that show what is happening to the process.
It is very important that the charts are beneficial and provide usefulinformation.
It is also necessary that the operators and foremen understand thecharts, or they may feel that they are an insult to their workmanship.
PREVENTATIVE INSPECTION One of the many benefits of Quality Control is that it places emphasis onprevention, rather than "after the fact" inspection.
We can not inspect goodquality into a a completed product; we can only sort out the defects and replacethem with good product.
This can be a very costly operation.
It is better tocontrol the product as it is being produced and eliminate defects before theyoccur than to try to sort them out afterwards.
SUMMARY
Many benefits of a Quality Control program are intangible and cannot bemeasured in dollars and cents.
Application of statistical quality controltechniques may be expected to:
A.
Improve product Quality B.
Reduce scrap and rework C.
Improve gauging equipment D.
Identify process capabilities E.
Identify product conformance to specifications F.
Provide better records G.
Reduce quality costs H.
Help provide better methods I.
Increase production J.
Provide information for tooling and process changes K.
Reduce labor of 100% inspection L.
Provide better control of purchased material M.
Serve as a clearing house between manufacturer and customer N.
Serve as a source to feed information back to design engineering