QUALITY SYSTEMS

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It is the maintenance of a
desired level of quality in a
service or product,
especially by means of
attention to every stage of
the process of delivery or
production.
Quality Assurance is different to Quality Control.
Quality Assurance does not check the quality of the
final product but the quality of all systems on the
production line, staff training and quality
monitoring. If this is to the highest standard the
quality of the final product should also be high.
Quality Control checks the quality of the product
at different stages of production.

The example below shows a production line that makes high quality boomerangs. These are 'batch'
produced which means, in this case, that one hundred boomerangs are made as a batch and then sent
to the customer. Quality control procedures are in place which means that after every stage of
making a Quality Control Officer checks the standard of the work. Any substandard work is recycled
or thrown away. The Quality Control Officer constantly checks that the boomerangs are being made
to a high standard. He patrols the production line and completes a ‘ Certificate of Quality’. This will
be included with each boomerang so that the customer knows that he / she has received a quality
product. The aim quality control is that the customer will be entirely satisfied by the product he/she
purchases. The final quality check is to test the boomerang in action. If it returns to the Quality
Control Officer then it has passed all the tests and can be sent to the customer.
 It’s stability - it must not
topple over.
It’s joints and fixings - should
be strong and shouldn’t break
Quality of finish - the colour
should be of high quality and
should be finish smooth and
polished

The European Community sets minimum

Products that have a British Standards
standards of safety and manufacturing quality,
Institute (BSI) Kite Mark stamped on them,
that apply across all member countries of the
have been checked for safety and quality of
EEC. Manufacturers working to this ‘lowest’
manufacture, by the BSI. The Institute carries
limit, can display the CE symbol on their
out strict tests, that have been designed to
products. Minimum standards have been
ensure that the product is safe and has been
established, that apply to a vast range of
manufactured to a high standard. The BSI
products, ranging from toys to motor vehicle
Kite Mark is respected throughout the world.
components. Manufacturers must ensure, that
If a product being tested meet British
their products at least meet these minimum
Standards, the manufacturer is issued with a
standards or risk having them removed from the
licence, allowing the use of the Kite Mark.
shelves of retailers throughout Europe.
When a product is manufactured in large numbers
by batch or continuous production it is almost
impossible to ensure that each individually
finished product is exactly the same. Each finished
product may look the same but there will be very
small differences. For example, the boomerang
shown below has been manufactured as one in a
batch of a thousand. Each boomerang will differ
very slightly in its size and shape due to the way it
has been manufactured. This is usually the case
when manufactured products are made completely
by hand or part manufactured by hand.

A company manufacturing
The quality and consistency of the
thousands of the M24 threaded
product. Each copy of the product
bolts seen below, ensures that each
is the same and works exactly the
bolt is manufactured within certain
same way. Products that have
tolerances. A simple tolerance
many parts, will fit together and
check includes checking that the
work in the way that they are
bolt is not too long or too short.
supposed to.
This is done with maximum size
Products that do not fit with the set
and minimum size gauges. If it is
tolerances, are rejected and do not
too long or too short, it will be
reach the customer.
rejected.
A standard component is usually an
individual part (called a ‘component’),
manufactured in thousands or millions, to
the same specification (such as size,
weight, material etc...). A good example
is a steel bolt. Bolts are available in a vast
range of standard sizes. However, each
size will be manufactured to an
internationally accepted standard. 

The Huf Haus is a Prefabricated House, built in the factory as

a flat pack and reassembled on site. This type of house is built
on an industrial scale. The design was inspired by the Bauhaus
designers of the 1920s, who approached design through
functionality and simplicity, combined with aesthetics. With
the Huf Haus, emphasis is placed modern design and a
distinctive style. Each house is constructed from standardised
components and are essentially a beam and post structure. The
beams form the framework on to which all other components
are fitted. There are no internal weight bearing walls to restrict
the internal layout. This frees up internal space, so that there
are a variety of layouts. The emphasis on glass, is another
distinctive feature of modernist buildings. 
 A risk assessment is a thorough
inspection of the processes and type of Identify, controls, and review
work carried out in the workplace, that
could give rise to injury / harm to
employees. A successful risk
assessment, should identify potential
hazards in the workplace and specify
safeguards, that minimise the risk of
injury / harm to employees.

A worker operates a drilling machine, to ‘drill’ holes in

sheet steel.  A hazard is something that can Fit Guard. Ensure guard is in
1. The employer identifies a hazard, as sharp steel swarf cause harm, e.g. electricity, position. Goggles supplied. Foot
being thrown towards the worker, at eye level and at
high speed. 
chemicals, working up a ladder, stop for emergency. Staff training,
2. The employer determines the risk (possibility of noise, a keyboard, a bully at so that drilling is controlled
swarf being thrown out) as high. work, stress, etc. A risk is the correctly by the operator and the
3. Precautions (control measures) are introduced, to chance, high or low, that risks are understood. Appropriate
protect the employee from harm and injury. He / she is
given safety goggles to wear, guards to use and safety
any hazard will actually cause protective clothing provided.
training.  somebody harm.
The control measures are written down clearly for
employees to follow.
 SCALES OF PRODUCTION
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Production
prototypes or production prototyping is the
act of designing and manufacturing a
product as close to the product deliverable
as possible. ... Typically the production
prototype will include
all production features designed or
required for the
target manufacturing process and final
part.
1. A highly specialised company.
2. Small highly skilled workforce, 
possibly one or two workers, sometimes more.
3. Constant communication with the client,
constant discussion regarding the design.
4. Company specialises in particular
areas such as engineering or musical instruments etc...
5. Specialist materials are often required
eg. specialist woods or modelling materials
6. The final product is expensive due to 
the level of skill needed to manufacture the
product and the cost of specialist materials
and equipment.
7. A high standard of quality control
8. Products are manufactured for 
a specialist market / clientele
eg. musicians, medical profession, aerospace.

The example specialist company (shown below)

has a small workforce. In this example one highly
Guitars, phone covers,
skilled worker manufactures the entire item. The
skilled worker is highly trained / skilled and
laptop covers, and
makes the product by hand. The example shown is
a specialist a specialist company manufacturing
handbags.
hand-made guitars. They design and make guitars
for professional musicians.

 
Batch production is a method used to produce 1. A production line is set up.2. Each worker completes one task and passing down th
similar items in groups, stage by stage. In production line to the next worker.3. The workers are semi skilled or unskilled.4. The
workers must be able to switch fromone part of the production line to another.They ar
batch production, the product goes through called a flexible workforce5. The production line can be changedquickly, so that differe
each stage of the process together before products can be made.6. Often individual parts of the product are bought from other
moving on to the next stage. The degree to companies and assembledon the production line.7. The production lines runs for a certa
amountof time and then the product is changed.
which workers are involved in this type of
production depends on the type of product. It
 
is common for machinery to be used for the  
actual production and workers
participate only at the beginning and end of
the process.

The example production line is

that of an engineering company, Chips, doughnuts,
manufacturing small steel products breads,
such as hinges and locks. They
manufacture batches of five
hundred at a time. The workers are
unskilled and semi skilled. As each
task is completed the item being
manufactured is passed down the
production line to the next worker,
until it is complete.
 Continuous manufacturing, also referred to as Process
Manufacturing (continuous), is a production line which
operates 24/7. The raw materials used for the
manufacturing process consist of gases, liquids, powders,
or slurries. Unlike other production lines that use more
physical components like found in repetitive and discrete
manufacturing.  The aim of the continuous
manufacturing flow is to produce a flow production to
manufacture, produce, or process materials
uninterrupted. The reason it is called a continuous process
is because the materials, which can also be fluids, are
being perpetually processed. During the
process, materials will experience chemical reactions or
mechanical or heat treatment.  6. Quality control at every stage of production. Sampling
It’s an Italian good that
is made with flour and
Pasta all of them need to have
the same shape - hence
continuous production
1. An semi-automated production line is normally set up.
Relying on computer control as well as human labour.
2. Workforce comprised of skilled and unskilled workers.
Workers less flexible than those working in batch
production
as the product rarely changes.
3. Production line runs 24 hours a day, 
365 days a year.
4. A high level of investment in machinery,
equipment.
5. Limited training of staff as the product and 
equipment changes slowly. Training only needed when
up-dated equipment is introduced or new staff start.
takes place at different stages of production.
Tomato sauce,
mayonnaise sauce, juice
production, and peri
peri sauce production.

‘Just in Time’ is a system based on efficient
organisation, from receiving a customer order,
the manufacture of the product on the
production line and finally distribution. This
system is often called ‘lean manufacture’. Just
in Time relies on a good, efficient working
relationship between the supplier / suppliers, the
manufacturer and the distributer. If one of the
links is inefficient, the entire system slows or
fails, leading ultimately to customer
dissatisfaction.
KFC chicken is produced
and fried right there and
then, and served just in
time
1. When an order for a batch of products arrives at the manufacturing
company, it is dealt with quickly and processed by administrative staff.
2. Materials / components are ordered from a supplier or suppliers.
Contractual agreements between the supplier and manufacturer, ensure that
they arrive at the manufacturing plant within twenty four hours (or sooner).
3. As soon as the materials / components arrive, they are processed on the
production line, so that the batch is manufactured without delay.
4. When the batch of products is ready, distribution to the customer takes
place. Distribution is often subcontracted to a haulage company.
5. When an order for a batch of products arrives at the manufacturing
company, it is dealt with quickly and processed by administrative staff.
6. Materials / components are ordered from a supplier or suppliers.
Contractual agreements between the supplier and manufacturer, ensure that
they arrive at the manufacturing plant within twenty four hours (or sooner).
7. As soon as the materials / components arrive, they are processed on the
production line, so that the batch is manufactured without delay.
8. When the batch of products is ready, distribution to the customer takes
place. Distribution is often subcontracted to a haulage company.
McDonalds, Burger King,
Taco Bell, In & Out.
Lean manufacturing is a methodology Lean Manufacturing and Just in Time, are often regarded
as the same, although they different in many ways. JIT
that focuses on minimizing waste concentrates on the efficient use of time and storing small
within manufacturing systems while amounts of stock/components, for use on the production
line. On the other hand, although efficiency is a core
simultaneously maximizing principle to Lean Manufacture, it must add value to the
productivity. ... Lean manufacturing is product and benefit the customer. In this way, JIT
based on a number of specific contributes to the Lean Manufacturing system. The
elimination of waste, is a core principle for Lean
principles, such as Kaizen, or Manufacturing, from receiving a customer’s order, to the
continuous improvement. production line and all the way to distribution. Eliminating
waste, must contribute to product improvement.

Lean manufacture
will only work Toyota, intel, John degree,
efficiently, if the
operational and nike
structure of the
An overbearing quality control company is
system, that interrupts
manufacturing on the production simplified. An
line, will also slow production
and add to costs. Lean
over complicated
manufacturing emphasises
simplification of all processes.
management
For example, it is important that system, or
all staff know their role within
the company and precisely what procurement
they are employed to do. This is
often achieved through
system, leads to
standardising tasks carried out by
employees.
inefficient
administration and
increased costs. 
Computer-integrated manufacturing (CIM) refers
to the use of computer-controlled machineries and
automation systems in manufacturing products. The integration
CIM combines various technologies like computer- of computer control
aided design (CAD) and computer-aided
manufacturing (CAM) to provide an error-free into manufacturing can streamline
manufacturing process that reduces manual labor systems, negating the need for
and automates repetitive tasks. The CIM approach
increases the speed of the manufacturing process time-consuming activities, such as
and uses real-time sensors and closed-loop control stocktaking, but also reducing
processes to automate the manufacturing process.
It is widely used in the automotive, aviation, space
the size of the workforce.
and ship-building industries

This is the complete automation of • FMS,

a manufacturing facility such as a (flexible manufacturing system)
factory. All functions are under
computer control. This starts with
• ASRS, automated storage and
retrieval system.
computer aided design, followed
by computer aided manufacture, • AGV, automated guided vehicle.
followed by automated storage • Robotics.
and distribution. One integrated
computer system controls all that •
happens.
 When designing and manufacturing it is usual
to carry out these functions in the same place.
For instance, for many decades the car
manufacturing industry in the UK designed and
manufactured cars on the same site. 
Today it is common to have designers in one
country sending their designs across the world
to another country where manufacturing takes
place. This is part of what is known as the
global economy. Often it is cheaper to
manufacture products in the Far East, in
countries such as China whilst designing in
Europe or the USA.
A typical example is seen
below. The book publishing
industry in the UK has seen a
shift in its printing
(manufacturing) from Europe to
Hong Kong or Korea. However,
the layout design and content of
books remains in the UK.

When designing and manufacturing it is usual to

• Expensive
carry out these functions in the same place. For
instance, for many decades the car manufacturing
• Relying on other
industry in the UK designed and manufactured
cars on the same site in the UK.
companies
Today it is common to have designers in one
country sending their designs across the world to
• Complex supply chain
another country where manufacturing takes place.
This is part of what is known as the global
economy. Often it is cheaper to manufacture
products in the Far East, in countries such as
China whilst designing in Europe or the USA.

A Flexible Manufacturing System
is one that can be changed or
adapted rapidly to manufacture
different products or components at
different volumes of production.
Flexible manufacturing systems are
usually seen at their most efficient
when manufacturing components
rather than finished products.
When machines are used to manufacture a
variety of products/components this is called
‘machine flexibility’. 
A good example is a company that specialises in
manufacturing injection moulded components.
The component design may change very quickly
but as long as the mould is updated / modified
the injection moulding machine can still
operate. Computers monitor the supply of
materials, monitor the operating temperatures
and quality control. Machines of this nature are
adaptable and are ideal for FMS.

When the manufacturing system is flexible

enough to absorb changes in manufacturing
capacity such as an increase in the number of
units being made this is called ‘routing
flexibility’. This may be achieved by selecting the
Chairs, clothing,
right path through which the product or
component flows through the production line. A
electronics etc..
production line that has enough manufacturing
capacity that can be utilised quickly is one that
has routing flexibility. For example a CD/DVD
manufacturing facility may have a number of
manufacturing units in standby mode until their
capacity is required. When not required units can
be shut down rapidly. This makes a manufacturing
plant more efficient.

Manufacturing industry chasing increased profits,
moves to the source of cheap labour, leaving
unemployment behind (e.g. the UK in the 1980s and
90s, hundreds of thousands of manufacturing jobs
were lost to countries such as China). This can cause
social unrest.
Increased economic well being leads to increased
pollution and environmental damage, as more and
more natural resources are used, as industrial and
agricultural production increases to satisfy the needs
of populations.
Some companies move their manufacturing to
countries where labour is cheap. Unfortunately, this
often means health and safety is ignored or is less
important, compromising the safety of workers.
Often working conditions are also difficult, such as
longer working hours and less holidays.
Globalisation can be summed up by the term
‘world trade’. People are now familiar with
products that are made by countries, other than
their own. Without globalisation, this would not
have been possible. Globalisation means that
there is free movement of products, services and
capital, across the borders of the world, helping
the world economy to grow. The worlds modern
transport infrastructure, now means that the flow
of labour, especially skilled labour is relatively
quick. This is another feature of globalisation.
The introduction of container ships, carrying shipping containers, led
the way for globalisation of trade. Large amounts of manufactured
goods could be loaded on to ships, transported and unloaded with
relative ease and relatively cheaply. An efficient international
distribution system is another feature of globalisation.
Cheaper products.
Increased availability and variety of products.
Cultural diversity, as people move around the world
following employment.
Flow of technical skills from one region of the world to
another, filling skill gaps.
Large numbers of people taken out of poverty, as the
world economy grows.
Increased trade and corresponding economic success.
The flow of ideas and education. 
Products more widely available, to poorer regions of
the world.
Flow of skills from one region of the world to another,
filling skill gaps.
The flow of ideas and education.
Disney, Apple,
Starbucks,
McDonalds, Sony,
Nike, Hp, CocaCola