Productivity and Quality Control-

UNIT -3
Concept Of Productivity

 Productivity is a tool of measurement that determines the

efficiency of the organization in terms of the ratio of output
produced with respect to inputs used.
  Various factors like technology, plant layouts, equipment, and
machinery affect productivity. Hence, operations managers need
to carry out a regular review of all these factors to maintain as
well as improve productivity.
Importance Of Productivity Control

 Equipment Improvement
 Plant Morale Improvement 
 Idle Time Reduction 
 Quality Improvement
Factors Influencing Productivity
Objectives of Production Control

1. To ensure maximum utilization of available resources thereby achieving lesser

cost of production.
2. To undertake the best and most economic production policies.
3. To make adequate arrangements for uninterrupted production by keeping in
view future obstacles in carrying production operations.
4. To introduce a proper system of quality control.
5. To ensure rapid turnover of production by minimizing inventories of raw
materials and finished products.
QUALITY CONTROL

 “The quality of a product may be defined as the sum of a number of related

characteristics such as shape, dimension, composition, strength, workmanship,
adjustment, finish and colour”.

 Control refers to the use of all the ways and means whereby quality standards could be
maintained. Control precisely aims at bringing the product up to pre­determined
standards by minimising deviations from established and present standards.

 Quality control is concerned with the control of quality of the product during the
process of production. It aims at achieving the predetermined level of quality in a
product. In other words quality control is concerned with controlling those negative
variances which ultimately affect the excellence of a manufacturer in producing the
products.
IMPORTANCE OF QC
Objectives Of Quality Control:
 To establish the desired quality standards which are acceptable to the customers? \

 To discover flaws or variations in the raw materials and the manufacturing processes in order to
ensure smooth and uninterrupted production.

 To evaluate the methods and processes of production and suggest further improvements in their
functioning.

 To study and determine the extent of quality deviation in a product during the manufacturing
process.

 To analyse in detail the causes responsible for such deviation.

 To undertake such steps which are helpful in achieving the desired quality of the product.
Quality control process

The steps to control product & process quality involves:

1. Establish controls

2. Test and check the Product/service

3. Analyse Variance

4. Check and Define Limits

MEASUREMENT TECHNIQUES AND TOOLS

 Cause-and-effect diagram (also called Ishikawa or fishbone diagrams)

 Check sheet
 Control chart
 Histogram
 Pareto chart:
 Scatter diagram
 Stratification:
Cause-and-effect diagram (also called Ishikawa or
fishbone diagrams)

 Identifies many possible causes for an effect or problem and sorts ideas into
useful categories.
IMPORTANCE

• To identify the possible causes of a problem.

• To help develop a product that addresses issues within current market
offerings.
• To reveal bottlenecks or areas of weakness in a business process.
• To avoid reoccurring issues or employee burnout.
• To ensure that any corrective actions put into place will resolve the issue.
Check sheet : A structured, prepared form for collecting and analyzing data; a
generic tool that can be adapted for a wide variety of purposes.
The check sheet is used for collecting, recording, and analyzing the data. Data
collection is an important activity in the problem-solving process as it provides a
basis for further action. Data may be numerical, observations and opinions, etc.
IMPORTANCE
1. Keeps You Organized :A check sheet is a handy tool for keeping all your data
organized.
2. Can Be Used To Record Results :A check sheet is particularly useful for
recording or collecting data as the event happens.
3. Easy to Understand and Interpret it : It is straightforward to use and interpret
the results.
4. A Good Starting Point for the Process Improvement: You can use a check
sheet to collect data that can be used for further analysis using tools such as a
Pareto Chart.
Control chart:

 Graph used to study how a process changes over time. Comparing current data
to historical control limits leads to conclusions about whether the process
variation is consistent (in control) or is unpredictable (out of control, affected
by special causes of variation).
 The main elements of a control chart include:
• A visual time series graph that illustrates data points collected at specific time
intervals.
• A horizontal control line to more easily visualize variations and trends.
• Horizontal lines, representing upper and lower control limits, placed at equal
distances above and below the control line. These upper and lower limits are
calculated from the data that is recorded on the time series graph over a
specified period of time.
Histogram:
 The most commonly used graph for showing frequency distributions, or how often each
different value in a set of data occurs.
 Often the mean of the data is indicated on the histogram. A bar chart is a series of bare
representing the frequency of occurrence of data characteristics, the bar height indicates
the number of times a particular quality characteristic was observed
Pareto chart: A bar graph that shows which factors
are more significant

 The pareto principle is based on the 80-20 rule. It means that 80 percent of the
problems/failures are caused by 20 percent of the few major causes/factors which are
often referred to as Vital Few
 And the remaining 20 percent of the problems are caused by 80 percent of many minor
causes which are referred to as Trivial Many. Hence, it gives us information about
Vital few from Trivial many.
 pareto charts can be used in several different ways, including:
1. To analyze the frequency of problems or defects in a process
2. To analyze broad causes by examining their individual components
3. To help focus efforts on the most significant problems or causes when there are many
4. To help communicate the significance of problems or causes to others
Each bar usually represents a type of defect or problem. The height of the
bar represents any important unit of measure — often the frequency of
occurrence or cost.
3) The bars are presented in descending order (from tallest to shortest).
Therefore, you can see which defects are more frequent at a glance.
4) The line represents the cumulative percentage of defects.
Scatter diagram: Graphs pairs of numerical data, one variable on
each axis, to look for a relationship. helps to analyze the relationship
between the two variables.
USES

• To analyzes strength & find out the relationship between two

variables.
• Provides the data to confirm a hypothesis that two variables are
related
• For Better process management in the variable analysis.
• Establish a relationship between two sets of numerical data.
• To track trends & patterns of different measures.
Stratification: A technique that separates data gathered from a
variety of sources so that patterns can be seen (some lists replace
stratification with flowchart or run chart).

 A technique used to analyze and divide a universe of data into

homogeneous groups called -Strata.
 It involves observing data, splitting them into distinct classes or
categories to see a different process for better analysis.
 In Stratification, data recording/observation carried out from
multiple sources like shifts, machines, days, people, etc.
Rejection data collected from three different machines and date wise trend chart
plotted. From the chart, we can see that machine-3 is contributing to high
defects/rejection as compare to machine-1. Therefore, the main focus area/source
is a machine no. 3 for necessary measures to reduce process variation and
rejection level.
Flowchart

 A Quality Control Flowchart is a guide used by employees in ensuring that the

production process runs according to the set criteria, so as with the employer
in targeting the expected output and maintaining quality management at a high
rate.
 Flowcharting is typically used to map a process flow showing the beginning of
a process, decision points, and the end of the process.
 They can identify bottlenecks, redundant steps and non-value added activities.
A realistic flow chart can be constructed by using the knowledge of the person
who are directly involved in the particular process. The flow chart can be
identifies where delays can occur
Quality Circle 

 "Quality circle is defined as a small group of employees doing similar or related work
who meet regularly to identify, analyze, and solve product quality and production
problems and to improve general operations. The circle is a relatively autonomous unit
(ideally about ten workers), usually led by a supervisor or a senior worker and
organized as a work unit".
 As the membership is voluntary, no incentive is given for joining, no punishment is
imposed for the non-participation, and there is no compulsion join it.
 Its are held meetings are during the working hours on the monthly or fortnightly basis
with an objective to scrutinize the issues related to the work which influence the quality
of production. 
Objectives of Quality Circles 

1. To contribute towards the improvement and development of the organisation by

enhancing its quality and output.
2. To bring down the cost of production by improvisation in methods of production,
enhancement of safety measures, reduction of wastage, elimination of as many flaws
and faults as possible, and optimum utilization of resources. 
3. To recognize and resolve the issues related with the work that hinders the
productivity. 
4. To bring out the creativity of the workers of the organization and thus make the
optimum utilization of the manpower.
5. To encourage interaction and reduce communication gaps inside the organization. 
6. To develop the ability, self-esteem, mind-set, and relationships of human resource.
Structure of Quality Circle 
Advantages of Quality Circles

 1) Work Group : 
• An optimistic atmosphere, which fosters team spirit, is established. 
• Members start feeling as a part of the company, which gives way to better job
satisfaction.
• It enhances the morale and self-esteem of the members as they feel that
their ideas are vital.
• The members of the group make efforts to enhance quality of their own
professional life.
• The interpersonal as well as technical skills of the workers are enhanced. 
• The ways to resolve the group conflicts are also formulated.
2) Management

 The QC is useful for the management in the following ways : 

• Quality circle brings relief to the management by solving the problem before it becomes
worse. 
• Better quality and enhanced output are secured by the managers. 
• More efficient workers are available to help the managers in the attainment of
organizational goals.
• Managers face lesser number issues related to grievances. conflicts, unpunctuality,
absenteeism, and other issues which adversely affect the productivity. 
• A relationship of mutual trust is established between the managers and members of the group.
• The training and experience of QC widens the knowledge and develop the skills of the
managers and their subordinates.
• It gives way to opening and smooth of functioning of various channels communication.
3) Organization

The QC is useful for the organization in the following ways : 

• The work performance of entire organization is enhanced, which advances the
process of achieving organizational goals. 
• It leads to better working abilities of the managers as well as their juniors.
• The workers have better and hence the number of human resource complaints
decline job satisfaction s.
• The focus of everybody is on working thoroughly and enhancing quality.
• There is better synchronization and coordination between the
management and the groups of workers.
• The execution and maintenance of quality circles is comparatively cost-
effective and thus saves a lot of funds.
Total Quality Management

 Total Quality management is defined as a continuous effort by the management as well as

employees of a particular organization to ensure long term customer loyalty and customer
satisfaction. Remember, one happy and satisfied customer brings ten new customers along with him
whereas one disappointed individual will spread bad word of mouth and spoil several of your existing
as well as potential customers.
 Total quality management ensures that every single employee is working towards the
improvement of work culture, processes, services, systems and so on to ensure long term
success.
 Total Quality management can be divided into four categories:
• Plan
• Do
• Check
• Act