QUALITY SYSTEMS

QUALITY SYSTEMS
QUALITY SYSTEM AND PROCESS IMPROVEMENT

The main goal of the manufacturing enterprise is to provide a product

with the best quality at a lower price and with the lowest operating
cost.
To accomplish this goal TWO quality management systems are used:
1. Prevention system: It involves statistical process control
(SPC), capability studies, and tool analysis.
2. Detection system: inspection, testing of parts & reliability
studies
Performing the goal to achieve quality also demands proper
documentation of a quality system.
For example, using ISO 9000 standards provide a framework to
establish a continuous improvement (CI). ISO 9000 is composed of a
set of four standards that provide quality systems for organisations that
design, develop, produce, install, and service their products.

The ISO 9000 quality system documentation:

1st level: Company level (Quality Manual)

2nd level: Department level

Who? What? Where? When? How?

3rd level : Machine, equipment, instruction.

How do you do it?
THE QUALITY IMPROVEMENT SYSTEM

Quality:
It is defined as the act to provide costumers with products and services
that consistently meet their needs and expectation.
“Consistently” means that there is minimal process variation
(machining time is the same, product specification is the same, product
performance is always the same, etc.).

Continuous Quality Improvement:

It is a systematic method of improving processes to better meet
customer needs and expectations.
“Plan-Do-Check-Act” Philosophy:
Dr. Deming proposed a philosophy for continuous improvement
(CI).
Plan: setting goals and plans.
Do: implement and accomplish the plan.

Check: gather data to find out what happened.

Act: after analysis of results, act to improve the process.

Based on this philosophy CI involves the following steps:
I- Planning and Education: each departments provides updates of the
quality policy to the highest management.

II- Customer / Supplier Analysis: The organisation should have an

understanding of the customer and supplier demands (Make sure that we are
making the right things).

III- Process Flow Analysis: Documentations of the organisation activities

and elimination of secondary unnecessary process. (Make sure we are doing
things right).
IV-Problem Analysis and Improvement: Problem identification, analysis,
measurement, solution, prevention. (Eliminate what we are not doing right).
V. Holding the Gains: After finding the best solution, a procedure must be
performed to maintain the profits gained (Maintain what we are doing right).
PROCESS VARIATION
PROCESS VARIATION
Variation is the inability to perform a task consistently according to
the customer specifications or demands.

This variation (dispersion) is

estimated by the variance (standard
deviation square 2).

Variance is the average squared

deviation from the mean of a set of
data. It is used to find the standard
deviation .
Sources of variation:
1. Process variability: the inability of the manufacturing process to
produce identical parts
2. Product degradation over its life cycle.
3. External factors.
4. Manufacturing process degradation.
Causes of dimension variation:
1.Chance, Common or Random Causes (Equipment accuracy,
weather, and material properties). These causes cannot be
controlled.
2.Assignable or Special Causes (worn-out equipment, improper
tooling, and material defect). These causes can be eliminated.
Quality Management

The aim of quality management is to identify and eliminate sources

that cause variation.
Monitoring Variations:
Statistical process control (SPC) is used to monitor and control
variation. SPC is a systematic method of tracking, predicting, and
minimising process variation. SPC results in cost reduction, quality
improvement, scarp and rework reduction, elimination of
unnecessary inspections, etc. SPC uses control charts.
Control charts are used to distinguish between random (variable data)
and the variation attributed to assignable causes.
CC-is achieved with a choice of control limits calculated using
probability laws. If the control limits are exceeded, the process is
considered out of control.
Data used for constructing CC can be:
1. Variable: measurable (quantitative) characteristics (length,
diameter, temperature, etc).
2. Attribute: non-measurable (qualitative) characteristics (good / bad,
go / no-go).
Accordingly, there are two types of control charts:

CC for variable data. CC for attribute data.

Control charts CC have the aim to eliminate assignable causes and minimise
random ones. Assignable variations do not follow any law and random variations
follow some statistical distribution.
 CONTROL CHARTS FOR VARIABLE DATA

X-bar Chart and R Chart

To understand statistical process control (control charts), let’s review
some terms:
1. Sample size: the number of parts to be inspected (3,4,5,6,7,…
parts in one sample).
2. Random sampling: taking a sample from a lot in which each part
has an equal chance of being included in the sample.
The sample is inspected for several characteristics such as tolerances,
surface finish, and defects. These characteristics fall into those two
categories described before (variable and attribute).
During the inspection of the diameter of different shafts, for example,
you soon note that their diameters vary, even though, ideally, you
want all the shafts to be exactly the same size.
If we group these diameters and plot them, the plot will consist of a
histogram (bar graph) representing the number of shafts in each
diameter group. From these bars a curve called normal distribution
curve is obtained.

Number
of shafts

Diameter of shafts
Normal distribution curve has two features :
1. It shows that most diameters tend to cluster around an average
value x = (x1+x2+x3+…+xn) / n
Where, numerator = the average value of all measured diameters in
one sample, n – number of measurements.
2. The curve width represent dispersion of the diameters, the wider
the curve, the greater the dispersion. The difference between the
largest value and the smallest one is called the range, R .

How are X – bar chart and R chart constructed?

1. Calculate the range R and average x of each sample.

2. Find the average of ranges R.
3. Find the average of sample averages x.
4. Calculate the control limits:
For x-bar chart: (UCLx , LCLx) = x ± A2R
For R chart: (UCLR , LCLR) = (D4R , D3R)
A2, D3, D4 – Constants (depend on the number of parts in one
sample).
5. Plot x-bar and R charts.
6. If the plot fall within the control limits (UCL, LCL), the process
can be under control. If not, so the process is out of control.
CONTROL CHARTS FOR ATTRIBUTE DATA

Used for qualitative characteristics: good/bad, go/no-go.

TYPES:
1. p-chart: used when the fraction of defective parts is desired.
2. np-chart: used when the number of defective parts is more
important.
3. c-chart: the number of defects per sample is desired.

4. u-chart: the number of defects per unit is desired.

Note: Defective  Product having one or more defects.

Construction of p-chart:
1. Find the fraction of defective parts in a sample:
pi = di / nI
di – number of defective parts,
ni – number of parts in the sample (sample size).
2. Find the average p of all pi.
3. Find the standard distribution: σ = p ( 1-p )
n
4. Find the control limits: (UCLp , LCLp) = p + 3.
PROCESS CAPABILITY ANALYSIS

It helps to decide on the behaviour of the process after eliminating

special causes of variation.