Role of QA&QC in Manufacturing -

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This presentation highlights the role of quality assurance and quality control in manufacturing

Text of Role of QA&QC in Manufacturing -

  • Growing a diversified global business

  • Quality Control ActivitiesContentsQuality Assurance Goal/ImplementationQuality Control Goal/ImplementationQuality Assurance ActivitiesQuality an overviewQuality Improvement Concept

  • Learning Objectives Quality Control Concept & ImplementationQuality Assurance Concept & ImplementationQuality Improvement - Concept

    Quality Inspection Plan

  • QA&QC Activities in Manufacturing 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.

    Quality Assurance

  • QA&QC Activities in Manufacturing Preparation of documentation and Quality related procedures

    Conducts Quality Review Meeting.

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

    Quality Assurance

  • QA&QC Activities in Manufacturing 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.

    Quality Control

  • QA&QC Activities in Manufacturing 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 Thinking that Quality is expensive; it lowers productivityThinking that Quality is intangible; it cannot be managedThinking that Poor quality means poor workersThinking that Quality is the responsibility of quality department onlyThinking that Quality is a DepartmentThinking that Quality is role specificThinking that Quality is someone elses jobThinking that Quality is not a major issue; it has little impact on the company


  • QA&QC - Improvement areas We must go back to the past. Back to the basics

    Basics .. Which Quality leaders have been advocating from many years

    Where should we go from here?

  • Overview

  • Quality Inspection PlanOverview

  • Overview

  • Quality Control 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 Inspection of products and services takes place during and at the end of the manufacturing processProblems: Not a value-added activityToo lateCostlyHuman factor in inspections

    Traditional QC

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

    Example Pressure Vessel Production

  • Quality Control

  • Quality Assurance 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

  • Quality Inspection PlanOverview

  • 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.

  • 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 ImprovementQuality Improvement

  • An example:FADEE ModelQuality Improvement

  • Quality Improvement

    Ordinary CompanyQI* CompanyQuality is expensive.Quality leads to lower costs.Inspection is the key to quality.Inspection is too late. Workers should produce defect-free goods, right at first timeDefects are caused by workers.Most defects are caused by the systemRewarding the best performers and punishing the worst will lead to greater productivity and creativityMost variation is caused by the systems that judge, punish, destroy teamwork.Profits are made by keeping revenue high and costs down.Profits are generated by loyal customers.

  • Quality Improvement

  • Quality Improvement Be a quality professional Who is quality professional?Starting point for improvement - recognize the needBe an agent for change in your organizationShow people how to prevent problems, not just identify themPromote qualitys image - Inside & outsideConstantly learn more about qualityEducate, train, and support those who do the work

    How can you make the difference?