1.

Introduction to Quality and Quality Control

1.2 Introduction to Quality Control :
Concept of quality control :
Quality control describes the directed use of testing to measure the achievement of a specified
standard.
Quality control is a superset of testing, although it often used synonymously with testing.
The concept of quality, namely that the object, the service, the performance whatever it is
should be fit for purpose.
Quality does not mean being at the top of the range, but it does mean being efficient (so things
happen on time and on cost), reliable (whatever the weather, every day of the week) and giving
good value for money.
The goal of quality control should be to identify process steps that best predict outcomes - A.
Blanton Godfrey

Link Among Quality, Productivity, and Cost :

Take an example.
A ring frame machine produces 1000 cops per day. The production cost per cop is Rs. 15. It is seen that
75% of the cops conform to specifications and 60% of the non-conforming cops can be reworked at an
additional expense of Rs. 5 per cop, the rest 40% of the nonconforming cops is scrapped.

The cost per good cop is

then

After implementation of process control program, it is seen that 80% of the cops conform to specifications
and 60% of the non-conforming cops can be reworked at additional expense of Rs. 5 per cop, the rest is
required to be scrapped.

The cost per good cop is then

Quality Control Methodology :

Statistical process control
Statistical product control
Six sigma
Total quality management (TQM)
Total quality assurance (TQA)
Note: TQM and TQA are beyond the scope of this course.

Statistical Process Control :

Statistical process control involves measurement and analysis of process variation by using
statistical techniques namely control charts.
This is most often used for manufacturing processes, in the intent of statistical process control is
to monitor product quality and maintain processes to fixed targets.

Statistical Product Control :

Statistical Product Control involves in making dispositions on accepting or rejecting a lot (or
batch) of product that has already been produced.
It is most often used to evaluate products that are received from outside sources and where it is
not possible to implement statistical process control.

Six Sigma :
Technical products with many complex components typically have many opportunities for
failure or defects to occur. Motorola developed the six-sigma program as a response to the
demand for such products.
The focus of six sigma lies in reducing variability in key product quality characteristics to the
level at which failure or defects are extremely unlikely.

References
1. Montgomery, D. C., Introduction to Statistical Quality Control, John Wiley & Sons, Inc., Singapore, 2001.

Sources of Further Information

1. Montgomery, D. C., Introduction to Statistical Quality Control, John Wiley & Sons, Inc., Singapore, 2001.
2. Grant, E. L. and Leavenworth, R. s., Statistical Quality Control, Tata McGraw Hill Education Private
Limited, New Delhi, 2000.
3. Leaf, G. A. V., Practical Statistics for the Textile Industry: Part I, The Textile Institute, UK, 1984.
4. Leaf, G. A. V., Practical Statistics for the Textile Industry: Part II, The Textile Institute, UK, 1984.
1. Introduction to Quality and Quality Control
1.1 Introduction to Quality :
Concept of Quality
Simply, quality refers to one or more desirable characteristics that a product should possess.
Quality is inversely proportional to (unwanted) variability.

Quality Characteristics:
Every product possesses a number of properties that jointly describe what the user or consumer thinks of as quality. These properties are known as quality characteristics.
For example, fiber length is known to be one of the important quality characteristics of a fiber.
Quality Cost :
Preventing, detecting and dealing with defects cause costs that are called quality costs or costs of quality.
Quality costs can be broken down into four broad groups.

(1). Prevention Costs:

product/process design.
Process control.

Burn-in.

Training.

Quality data acquisition and analysis.

(2)Appraisal Costs:
Inspection and test of incoming material.
Product inspection and test.

Material and services consumed.

Maintaining accuracy of test equipment.

(3).Internal failure Costs:

Scrap
Rework

Retest

Failure analysis

Downtime

Yield losses

Downgrading/ off-spacing

(4). External failure costs:

Complaint adjustment
Returned product/material

Liability costs

External costs

Quality history [1]

Year

Event

1700-1900

Quality was largely determined by the efforts of an individual craftsman.

1915-1919

WWI- British government began a supplier certification program.

1919

Technical Inspection Association was formed in England, this later becomes the Institute of Quality Assurance.

1924

W A Shewhart introduced the concept of control charts in Bell Laboratories technical memorandum.

1928

Accepatance sampling techniques were developed and refined by H. F. Dodge and H. G. Romig at Bell Labs.

1931

W. A. Shewhart published Economic control of quality of manufactured product outlining statistical methods for use in production and
control chart methods.

1932-1933

British textile industry began use of statistical techniques for product/process development.

1944

Industrial Quality Control began publication.

1954

E. S. Page introduced CUSUM control chart.

1960

The concept of quality control circle was introduced in japan by K. Ishikawa.

1960

The zero defects (ZD) programs are introduced in US induatries.

Copyright IIT Delhi 2009-2011. All rights reserved.