Role of QA&QC in Manufacturing & Improvement Areas

Growing a diversified global business

Contents
Quality Assurance Activities Quality Control Activities Quality an overview Quality Control Goal/Implementation Quality Assurance Goal/Implementation Quality Improvement Concept

Learning Objectives

Quality Control
Concept & Implementation

Quality Assurance
Concept & Implementation

Quality Improvement - Concept

QA&QC Activities in Manufacturing

Quality Assurance

Implementation of QMS.

Control, update and revision of QMS documents .

Conduct internal Audit and coordinates with ISO certified body for certification. Coordinate with client for external / third party audits Maintain and control the Manual and SOP/MS/Written Practices. Control and monitoring of NCRs / CARs. Second party audit of vendors and subcontractors.

QA&QC Activities in Manufacturing

Quality Assurance

Preparation of documentation and Quality related procedures

Conducts Quality Review Meeting.

Review and analyze customer complaints and other re-occurring problems in the process.

QA&QC Activities in Manufacturing

Quality Control

To carry out stage and final Inspections & preparation of associated reports. Client and Customer cordination and handling. Material inspection during receiving and before issuance to fabrication. Welding control and monitoring of repair rates Supervision of non-destructive testing.

QA&QC Activities in Manufacturing

Inspections

Incoming goods inspection.

Marking & layout inspection.

Fit up inspection . Weld visual inspection. NDT Review ,Witness & Clearance. Hydro test witness Surface preparation & painting inspection Packing & Shipment inspection

QA&QC - Improvement areas

Concepts????

Thinking that Quality is expensive; it lowers productivity Thinking that Quality is intangible; it cannot be managed Thinking that Poor quality means poor workers Thinking that Quality is the responsibility of quality department only

Thinking that Quality is a Department

Thinking that Quality is role specific Thinking that Quality is someone elses job Thinking that Quality is not a major issue; it has little impact on the company

QA&QC - Improvement areas

Where should we go from here?

We must go back to the past. Back to the basics

Basics ..

Which Quality leaders have been advocating from many years

Overview

Overview

Overview

NDE Spool Erection & Welding Pressure Testing Welding visual inspection Bevel, Fit-up, Alignment etc

DESCON

Quality Control
Concept

Process of making sure that products or services are made to consistently high standards It is product oriented It coordinates the links between the following activities:

Specifications of what is required. Components, elements of the product Inspection of the product to determine conformance to customer specification.

Quality Control

Quality Control

Quality Control
Traditional QC

Problems:
Not a value-added activity

Too late
Costly Human factor in inspections

Inspection of products and services takes place during and at the end of the manufacturing process

Quality Control
Example Pressure Vessel Production

Raw material

Final Product

Quality Control, only, is not enough Inspections for defects too late

Quality Control

Quality Assurance
Concept

A set of activities designed to ensure that the development and maintenance process is adequate to ensure a system will meet its objectives. A process of verifying or determining whether products or services meet or exceed customer expectations.

A process driven approach with specific steps to help define and attain goals.
Quality assurance defines the quality policy and in turn, how to follow the policies in better way to avoid any issues/defects thus saving time effort and money in the production of product but also providing the customer with exactly what they require.

Quality Assurance

HOW SURE ARE YOU?? :: focus on the process involves, and make sure you do the right thing. To ensure that the products/services meet the customers requirements at the highest standard. :: customer requirement/needs may change in time. Determine if the steps/process implemented to produce the product/service are appropriate with the time and conditions.

Quality Assurance

Internal audit / First party audit :: a systematic, independent and documented process, conducted by members within the organization and obtain evidence and evaluate it to determine where requirements are fulfilled. External audit / Second or Third party audit :: similar to internal audit, but conducted by members not within the organization.

Quality Assurance

:: PDCA analyzes existing conditions and methods used to provide the product or service to customer.

QC vs QA

Quality control emphasizes testing and blocking the release of defective products,

Quality assurance is about improving and stabilizing associated processes to avoid or at least minimize issues that led to the defects in the first place.
However, QA does not necessarily eliminate the need for QC: some product parameters are so critical that testing is still necessary just in case QA fails

Quality in an Organization

Overview

Quality Improvement

Keyword : IMPROVEMENT The continuous study and improvement of a process, system, or organization A continuous process that identifies problems, examines solutions to those problems, and regularly monitors the solution implemented for improvement. Example in manufacturing / industry : reduce product failures or work related injuries. Example in administration / service : increase efficiency or reducing re-work.

Quality Improvement

It is aimed at improvement - measuring where you are, and figuring out ways to make things better. It specifically attempts to create systems to prevent errors from happening. QI activities can be very helpful in improving how things work. Trying to find where the defect in the system is, and figuring out new ways to do things can be challenging and fun. Its a great opportunity to think outside the box.

Quality Improvement

Five (05) crucial activities to Quality Improvement

Quality Improvement

An example:

FADEE Model

Quality Improvement
Ordinary Company Quality is expensive. Inspection is the key to quality. QI* Company Quality leads to lower costs. Inspection is too late. Workers should produce defect-free goods, right at first time

Defects are caused by workers.

Rewarding the best performers and punishing the worst will lead to greater productivity and creativity Profits are made by keeping revenue high and costs down.

Most defects are caused by the system

Most variation is caused by the systems that judge, punish, destroy teamwork.

Profits are generated by loyal customers.

Quality Improvement

Quality Improvement
How can you make the difference?
Be a quality professional Who is quality professional?

Starting point for improvement - recognize the need

Be an agent for change in your organization Show people how to prevent problems, not just identify them Promote qualitys image - Inside & outside Constantly learn more about quality Educate, train, and support those who do the work