REPORT OF A STUDY ON

“INSPECTION AND QUALITY CONTROL” IN

MANUFACTURING
A mini report submitted in the partial fulfillment of the requirement for the award of degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

Submitted by

KUDA PRASANTH – 318107020024

ANDHRA UNIVERSITY COLLEGE OF ENGINEERING

VISAKHAPATNAM
 ABSTRACT

Designing quality-inspection procedures may be difficult for short-run manufacturing processes,

due to poor effectiveness of the classical statistical process control (SPC) techniques for these
processes. This paper proposes a practical methodology to guide quality designers in selecting
the more effective and economically convenient inspection procedures. First, the process of
interest is decomposed into a number of steps, in which specific defects can occur. Next,
several parameters related to inspection effectiveness and cost are combined into a
probabilistic model. The more effective and economically convenient inspection procedures can
finally be determined using two specific synthetic indicators. A case study concerning a short-
run production of hardness testing machines is presented and discussed.

The optimization of quality costs in manufacturing was investigated and efficiency of a total
quality program was analyzed. Traditional view of optimal distribution of quality costs has
been abandoned. It has been found out that optimal quality costs respond to total quality
control or to the zero defect level. Quality management cannot be successful without quality
cost management. The activity of manufacturing quality system as cost centers have been
defined. The manufacturing quality costs have been classified in categories. In total quality
control there is a reduction in all quality cost categories and quality is increased. A ratio
between the prevention costs and failure costs as measure of efficiency of an achievement of
a total quality program is decreased in accordance of implementation of a total quality
program.
 ACKNOWLEDGEMENT

With pleasure I extend my deep sense of gratitude to my supervisor PROF.P.SRINIVAS

KISHORE, Department of Mechanical Engineering, ANDHRA UNIVERSITY COLLEGE OF
ENGINEERING, Visakhapatnam, for his Honorable guidance and encouragement. Without his
valuable views this study would not have been the light of day.

I would take this opportunity to thank PROF.K.VENKATA SUBBAIAH, Head of the Department,
for giving me the opportunity to explore and get acquainted to the corporate world.

Lastly, I would sincerely like to thank PROF. KAUSHIK PAL, Department of Mechanical
Engineering, IIT Roorkee for his valuable suggestions and cooperation given in doing the work
on this term paper

Yours Sincerely

KUDA PRASANTH
 Contents

 Acknowledgement

 Abstract

 Introduction
 Fundamental Concepts of Quality, Inspection and their
Role in Manufacturing
 Need of Inspection and types

 Testing of Materials
 Destructive Tests
 Non-Destructive Tests

 Results

 Conclusion

 References
 Introduction: Fundamental Concepts of
Quality, Inspection and their Role in
Manufacturing

Inspection
Definition: Measuring, examining, testing and gauging one or more characteristics of a product
or service and comparing the results with specified requirements to determine whether
conformity is achieved for each characteristic.

 Inspection can be performed at several places in production: from acceptance of the and
parts from the suppliers to the shipping of the products to the customers.

• Inspected products can be the components used for production, work-in-process finished
goods.

• For manufacturing systems which are in continuous operation and subject to breakdown,
inspection can be an appropriate maintenance strategy.

Role of Inspection in Manufacturing:

“intellectuals solve problems, geniuses prevent them”

 Inspection: Watchdog of a manufacturing process.

 Inspection is performed in an manufacturing industry to prevent the defects from passing
further down the line and to make the product as per the required specifications.

 Inspection is done to minimize the rework and scrap costs in manufacturing.

Functions of Inspection:

Inspection is normally carried out:

1. To find out physical imperfections (such as surface defects and internal defects etc.).

2. To check the quantity (such as numbers, volume, and weight etc.).

3. To check the physicaI dimensions (such as length, width, height, and thickness etc.).

4. To check the nominal size (usually done for the bulk raw materials).

5. To check the physicaI appearance (such as brightness, Dullness, Rusting, Weathering,

colour, solid, liquid etc.).

6. To check the chemical composition.

7. To check physical, mechanical, and electrical properties like density or specific gravity,
dimensional tolerances, product shape, temperature, tensile strength, microstructure,
fracture analysis etc.

8. To check man other properties which are specific to certain products such as coaling
thickness in case of coated products, refractoriness and apparent porosity etc.

Basic Issues of Inspection:

• The purpose of inspection is to provide information on the degree to which items conform to
a standard.

Where to inspect?

• Inspection always adds to the cost of the product: therefore it is important to restrict
inspection efforts to the points where they can give the more advantage.

 In manufacturing, some of the typical inspection points are:

Stages of Inspection and Testing:

 I. Incoming materials inspection and Testing:

 Incoming Inspection is called as Raw Material Inspection and it is done br the purchase
order.

 This procedure covers inspecting purchased supplier material i.e. raw material,
purchased parts, subcontracted goods etc.

II. In –process material inspection and testing:

 It is performed when the product is transferred from one process to the next.

 Its purpose is to prevent defected goods from entering the next process and producing
further damage.

III. Semi-finished product inspection and testing:

 It is performed for processed parts, and assemblies, and it does not include the
completely finished goods.

IV. Finished product inspection and testing:

 It is the inspection performed in the final stage of manufacturing process.

 In this test, whether the complete goods meet the requirements as a product or not is
determined in order to prevent the loss in customer confidence, various problems, and
damages in advance.

How much to inspect?

• The amount of inspection can range from no inspection to inspection of each item many
times.

• Low-cost, high volume items such as paper clips and pencils often require little inspection
because:

 The cost associated with passing defective items is quite low.

  The process that produces these items are usually highly reliable, so that defects are
rare.

• High-cost, low volume items that have large cost associated with passing defective items
often require more intensive inspection such as airplanes and spaceships.

• The amount of inspection needed is governed by the cost of inspection and the expected cost
of passing defective items.

Optimal Amount of Inspection :

• The complete setup and execution of inspection activities increase total production cost.

• Total inspection cost is the sum of the fixed cost and the variable cost, in which the variable
cost is related to the quantity inspected per day.

• The fixed cost includes the setup cost and salaried workers of the inspection area.

• For calculating the optimal amount of inspection, the variable cost is taken into consideration.
Whether to Inspect Attributes (Counts) or Variables (Measures)?

 Basically, there are two types of data to collect as part of a inspection procedure:

a) Attribute (Discrete) Data:

 Quality characteristic for which a numerical value is not specified.

 It is a qualitative data that can be counted for recording and analysis.

 For example: taste, paint quality, quality of output, no. of defects. no. of defectives, no.
of scrap items etc.

b) Variable (Continuous) Data:

 It is a measurement information of the product.

 For example: length, volume, time, etc.

 They are both important information, but variable data is generally more useful as it is more
precise and contains more information.

Drawbacks of Inspection:

 Inspection merely separates good and bad items. It is no way to prevent the production
of bad items.

 Inspection adds to the cost of the product but not for its value.

 It requires more man power/operations to maintain quality control and adds more time
to the initial process.

 It is partially subjective, often the inspector has to judge whether a product passes or
not.

Example: Inspector discovering a slight burnish on a surface must decide whether it is bad
enough to justify rejection even with micrometres a tight or loose fit change measurement by
say 0.0006 inches. The inspectors design is important as he enforces quality standards.

 Fatigue and Monotony may affect any inspection judgement.

Quality
 Quality has no specific meaning unless related to a specific function and/or object.

 The definition of “quality” has changed over time, and their various interpretations arc
given below:

 The totality of features and characteristics of a product or services that bear

on its ability to satisfy stated or implied needs of the customers (ISO).
 Quality of a product or service is the fitness of that product or service for
meeting its intended USC required by the customer (JOSEPH JURAN).
 Quality is conformance to specifications (EDWARD DEMING).
 Quality is conformance to requirements (PHILIP CROSBY).
 Quality is what the customer says, it is (FEIGEN BAUM).

 The common element of the above definitions is that the quality of a product or service
refers to the perception of the degree to which the product or service meets the
customer’s expectations.

 Perceived quality is governed by the gap between customers expectations and

their perceptions of the product or service.
Dimensions of Product Quality:

As prescribed by Garvin, the eight dimensions of quality are:

1. Performance (will the product do the intended job?)

2. Conformance (does the product meets the specifications?)

3. Reliability (how often the product fails?)

4. Durability (how long the product lasts?)

5. Serviceability (how easy is to repair the product?)

6. Aesthetics (what does the product looks, feels, sounds, smells, or tastes?)

7. Features (what does the product do? For example extra features added to basic
features.)

8. Perceived quality (what is the reputation of a company?)

Cost of Quality:

• Money spent beyond expected production costs (labour, materials, equipment) to ensure
that the product the customer receives is a quality (defect free) product.

• It quantifies the total cost of quality-related efforts and deficiencies in manufacturing a

product.
Four Cost Categories Related to Quality :

 Prevention Cost

o Cost of planning and executing a project so it is error free or within an acceptable

error range.

 Example: Cost of training and performing acceptance sampling of raw materials,

SQC, Six Sigma, and other techniques.

 Appraisal Cost

o Cost of evaluating process and their outputs to ensure quality.

 Example: Cost of detecting defects in the final product i.e. outgoing inspection of
products before king shipped to customers.

 Internal Failure Cost

o Cost incurred to correct an identified defect before the customer receives the
product.

 Example Cost of scrap and rework of defective products. This includes the extra
piper work, delays, rescheduling required, etc.
  External Failure Cost

o Cost that relates to all errors not detected and correct before delivery to the
customer.

 Example: Cost of Warranty Claims. This also includes the loss of goodwill on the
part of customers.

Impact of Quality Management on Costs:

• Total cost of quality is ultimately reduced by investing money up front in quality design and
development.

• Increasing the effort spent on preventing errors occurring in the first place brings a more than
equivaIent reduction in other cost categories.
Quality Control
Definition: Inspection, analysis and action applied to a portion of the product in a
manufacturing operation to estimate overall quality of the product and determine what, if any,
changes must be made to achieve or maintain the required level of quality.

 It involves inspection and testing of units and determining if they are within the
specifications for the final product.

 The purpose of the testing is to determine any needs for corrective actions in the
manufacturing process.

Benefits of Quality Control:

 Quality is vital in all areas of business, including the product development and
production functions.

 A well established, committed quality system in an organization will render the

following benefits:

 Defect reduction
 Higher productivity
 Cost reduction
 Continuous improvement in quality of product
 Customer satisfaction
 Need of Inspection : Types and
principles
 Inspection is an indispensable tool of modern manufacturing process.

 It helps to control quality, reduces manufacturing costs, eliminate scrap losses and
assignable causes of defective work.

 It has mainly two uses:

1. Quality Control - before the component is used in service.

2. Maintenance and Health Monitoring - while the component is in

service.

 Inspection is the most common method of attaining standardization, uniformity and

quality of workmanship.

 It is the art of controlling the product quality after comparison with the established
standards and specifications.

Purpose of Inspection:

The purpose of inspection is:

 To distinguish good pieces from bad pieces.

 To determine if the process is changing.

 To rate quality of product.

 To rate accuracy of inspectors.

 To measure the precision of the measuring instrument.

 To secure products-design information.

 To measure process capability.

 Inspection Types

Classification of Inspection:
 Testing of materials

 Many parts are formed into various shapes by applying to the

external forces to the workpiece.
 Material testing is a test done to determine the properties of a
substance in comparsion with a standard or specification.

Purpose of material testing :

 To determine the quality of material.
 To determine the mechanical properties such as strength,
hardness, Ductility, toughness, etc.
 To trace defects / flaws in the materials.
 To evaluate the materials potential in certain use.

 Material of testing can be divided into two categories :

Destructive Testing and Non-Destructive Testing

 Destructive Inspection
 Destructive tests are carried out to the specimen’s failure, in order to understand a
specimen’s performance or material behaviour under different loads.

 These tests are generally much easier to carry out, yield more information, and arc
easier to interpret than non-destructive testing.

 While destructive testing is intrinsically more revealing: it also is costly to a

manufacturing operation due to material loss and, for obvious reasons, it is not suitable
for in service material testing.

Examples :

Destructive Testing of Materials:

 Non-destructive Inspection
 Non-destructive inspection or Non-destructive evaluation (NDE) is a method of
materials testing to assess the characteristics of a component without altering or
destroying it.

 NDT is important in the materials testing industry where quick, dependable information
on finished or raw material is needed.

 This may occur during the production stage, during the service life of a material or
product, or as a diagnostic tool in the event of material failure.

 NDT is contrary to destructive testing such as stress or bend testing where critical
material properties are determined through achieving specimen failure.

Examples :
 RESULTS

It is important for an organization that the quality of the products is maintained when they are
delivered to the customers since the product quality is the top most drivers for the success of
the organization. However, in the organization, employees do make mistakes and machines and
equipment do have breakdowns. These results into the production process getting destabilize
which in turn cause production of the products which do not meet with the requirements
specified in the standards and specifications. Hence, there is necessity of inspection and testing
so as to ensure that the products delivered to the customer are complying with the
specification as required by the customer.

Inspection and testing measure and determine the quality level of the products. These are the
activities or techniques used to verify the product quality as well to ensure that the results of
the manufacturing process are the same as was expected. Inspection and testing activities are
done to uncover the defects in the products and reporting to the production management who
make the decision to allow or deny product release.

Quality control is designed to detect, reduce, and correct deficiencies in a laboratory’s internal
analytical process prior to the release of patient results. Quality control samples are special
specimens inserted into the testing process and treated as if they were patient samples by
being exposed to the same operating conditions. The purpose of including quality control
samples in analytical runs is to evaluate the reliability of a method by assaying a stable material
that resembles patient samples. Quality control is a measure of precision or how well the
measurement system reproduces the same result over time and under varying operating
conditions.
 CONCLUSION

In evaluating data gathered and systematic analysis of the reports in the course of the study
regarding the impact of INSPECTION AND QUALITY CONTROL IN MANUFACTURING on
corporate performance and productivity in the brewery sectors, the following conclusion can be
drawn:

 There are signs that INSPECTION AND QUALITY CONTROL IN MANUFACTURING

concepts improves the performance of an organization in terms of cost reduction,
increase in corporate performance and productivity, profitability and market shares,
competitiveness and customer satisfaction;

 The concept of INSPECTION AND QUALITY CONTROL IN MANUFACTURING has been

highly welcomed in the company as a way of life for customer satisfaction, making the
customer delighted as well as staff and in achieving corporate goals and objectives.

 Thus INSPECTION AND QUALITY CONTROL IN MANUFACTURING forms an integral part

of company’s management

Finally, the importance of INSPECTION AND QUALITY CONTROL IN MANUFACTURING in

achieving business success can hardly be denied Peters and Waterman (1982) found inspection
and quality to be an important in the pursuit of excellence. Quality is therefore the best
assurance of customer allegiance, strongest defence against competition and the only path to
sustained company growth and earnings. Whereas Inspection is to inspect the areas of all the
things in proper maintenance in very company assests for their benefitial manufacturing.
 REFERENCES

AASHTO, 1996, “Implementation Manual for Quality Assurance,” American Association of state
Highway and Transportation Officials, Washington, D.C

Weed, Richard M., 1996, “Quality Assurance Software for The Personal Computer.
Demonstration Project 89, Quality Management,” FHWA-SA-96-026.

The Man Who Discovered Quality (1990) by Andrea Gabor. Times Books (a division of Random
House, N.Y.) “… a comprehensive review of the influence Deming has had to date in America
and Japan,,[and] an acute assessment of how his theories might be implemented in the future.”

Newman, Robert B., June 1989. “Use of Consultants for Construction Engineering and
Inspection.” NCHRP Synthesis of Highway Practice 146, Washington, DC.

Maier EA (1991) Certified reference materials for the quality control of measurements in
environmental monitoring. Trends in Analytical Chemistry