AN INDUSTRIAL TRAINING

REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

IN

MECHANICAL ENGINEERING
BY
NITIN CHANDRAKANT DUDHAVADE
AT
GENERAL MOTORS COMPANY LLC

DEPARTMENT OF MECHANICAL ENGINEERING

DR. D.Y. PATIL POLYTECHNIC AKURDI, PUNE –

44

(Affiliated To MSBTE, DTE Mumbai) 2019 – 2020

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 1

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATIONPage 2
 Maharashtra State

Board of Technical education

Certificate of Completion
Of Industrial Training

This is to certify that Mr. Nitin Chandrakant Dudhavade

With Enrollment No. 1801340177 has successfully completed

Industrial Training (22049) in__ ___ ___ ___ ___

from ____ ___ ___ ___ ___ to _ ___ ___ ___ ___ ____ for
partial fulfillment towards completion of Diploma in ___ ___ ___ _

from ____ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ __

Institute Code - ____ ___ __ _____

Seal of the

Head of the Department Institute Head of the Institute

ABSTARCT
 ACKNOWLEDGEMENT

I am highly grateful to our honorable Principal Mr. A.S. Kondekar for allowing me to

do this project work. I am also thankful to our Head of Department Mr. D.V.

Moghekar. It is truly a matter of great pleasure me to express my sincere thanks and

gratitude to Mr. Chandru Pattanshetty for his supervision and encouragement

throughout this project. I am immensely indebted to Mr. Chandru Pattanshetty for

the invaluable help that he rendered at every step of this project. It is a wonderful

experience to be a part of. “General Motors Company” Where we work under brilliant

minds. We owe our deep regards for the supporting and kind staff authorities who are

helping me In my lean patches during these two months. The knowledge we are

gaining throughout our studies have the practical implementation during this period.

We are grateful to all the staff of “Y.B PATIL POLYTECHNIC AKURDI”

 INDEX

SR
TITLE PAGE NO.
NO.

1.
Certificate Of Completion

Abstract
2.

3. Acknowledgement
Chapter 1 :- Introduction Of
4. Organization
Chapter 2 :- Organizational Structure
5.
Chapter 3 :- Types Of Machines &
6. Instruments
Chapter 4 :- Manufacturing Processes Of
7. Production
Chapter 5 :- Testing Of Raw Materials
8.
Chapter 6 :- Quality Policies Of Company
9.
Chapter 7 :- Range Of Products
10.
Chapter 8 :- Vision & Mission Of
11. Company
Chapter 9 :- Expansion Of Company
12.
Chapter 10 :- Turnover Of Comapany
13.
Chapter 11 :- Furure Plans
14.
Chapter 12 :- Milestones Of Company
15.
Process:- Quality Control In Detail
16.
 CHAPTER I

 Introduction:-

General Motors (GM), one of the world's largest auto manufacturers, makes and sells

cars and trucks worldwide under well-known brands such as Buick, Cadillac, Chevrolet,

GMC, and Holden. Business divisions GM North America and GM International handle

the automotive end of the business while General Motors Financial Co. provides

financing services. Looking toward the future of transportation, the company is

investing in developing electric vehicles and autonomous vehicles, and it

has established a ride-sharing service dubbed Maven. GM's biggest single market is

the US, which accounts for about 80% of sales. General Motors Co designs, builds

and sells trucks, crossovers, cars and automobile parts worldwide. The Company

also provides automotive financing services through General Motors Financial

Company, Inc. (GM Financial). GM North America (GMNA) and GM International (GMI)

are its automotive segments. GMNA and GMI are meeting the demands of customers

with vehicles developed, manufactured and/or marketed under the Buick, Cadillac,

Chevrolet and GMC and Holden brands. Its brands offer luxury cars, crossovers, sport

utility vehicles (SUVs) and sedans. The Company’s Car-and Ride-Sharing Maven is a

shared vehicle marketplace. Through its subsidiary, OnStar, LLC (OnStar), it provides

connected safety, security and mobility solutions for retail and fleet customers. GM

Cruise is its global segment engaged in the development and commercialization of

autonomous vehicle technology.

 History:-

General Motors was founded in Flint, Michigan in 1908. In the early years of the auto

industry, hundreds of carmakers each produced a few models. William Durant,

who bought a failing Buick Motors in 1904, reasoned that manufacturers could benefit

from banding together and formed the General Motors Company in Flint, MI in 1908.

In 1909, GM purchases Cadillac, AC Spark Plug, and Rapid Motor Vehicle

Company. It later developed the General Motors Truck Company (which later

became GMC), Chevrolet Motor Company of Michigan, General Motors Export

Company, and general Motors of Canada. After the stock market crash of 1929, GM

bought out the Fokker Aircraft Company and the General Motors Aviation Company

was launched. During WWII, the company began making military vehicles including

trucks, guns, airplane engines, airplanes and parts, tanks, and shells among

other products. It also provided the mobility system for the Lunar Roving Vehicle

during the 1971 Apollo 15 space mission to the moon. General Motors has

manufactured some of the most popular vehicles ever made including the Cadillac,

Corvette, El Camino, Malibu, and Camaro. The auto giant went through a six-week

period of bankruptcy protection in 2009. GM was split into two companies — General

Motors and Motors Liquidation (the name for leftover assets). In 2011 Motors

Liquidation sold the majority of its assets, which encompassed almost 90 industrial

sites in 14 states, which cleared the way for GM bondholders to receive stock in the

new company
 CHAPTER II

 Organizational Structure Of General Motors Company:-

 Board Members & Advisors Of GM:-
 CHAPTER III

 Types Of Machines & Instruments In GM:-

 Welding Robot:-

There are two basic categories of robotic welders: fully automatic, and
semiautomatic:-

Semiautomatic welding, often good for limited quantities of products, requires

an operator to manually load the parts into the fixture. In fully automatic welding –

ideal for critical welds, repetitive work on identical parts, or if the parts are

already hold significant value – there are custom machines, or sometimes even a

series of custom machines, set up to load parts, move the torch, weld, monitor the

quality of said weld, and then unload the completed part.

 Painting Robot:-
> CNC Machines:-

 Overhead Conveyor:-

 Stamping Dies:-
 CHAPTER IV

 Manufacturing Processes Of Production:-

GM has adopted a number of innovations to reshape its manufacturing operations. An

innovation called the GM agile machining fixture introduced a process known as

flexible manufacturing that enables power train facilities to run different engine or

transmission families across common machining lines. This manufacturing technology

allows for a significant reduction to the setup and tooling costs that are typically

incurred during product changeover. Other innovations include a computer-based

vision system, known as the Video Variance Monitor, and web-based software called

the Variation Reduction Adviser. The introduction of these applications enables GM

body assembly plants to quickly zqdiagnose and resolve quality issues. Employees at

the plant view and analyze body shop operations in real-time and share problem-

solving data on a variety of issues within the plant and across all GM’s assembly

centers. In addition to the efficiencies gained through the manufacturing innovations

above, GM operations have also benefited from a company-wide energy saving

initiative. GM’s product mix varies by country. In the U.S the company currently offers

a lineup of 63 different vehicle models, spread among nine different product areas.

These product areas include coupe, sedan, hatchback/wagon and sport/convertible

cars, as well as, sports utility, crossover vehicles and pick-up trucks. In addition,

GM also offers vans and hybrid/electric vehicles. Today, our vehicle manufacturing

process has the lowest environmental footprint in our history, thanks to steady

progress toward achieving our 2020 operational commitments to reduce energy,

carbon, water and waste intensity.

MANUFACTURING:-

It is responsible for assembling various components of the car to make the final

product. Manufacturing department consists of the body shop, where the sheet metal

parts are all assembled and the basic BIW (Body In White) structure of the body is

made; paint shop, where the body and its assembly parts are chemically treated and

painted; and finally Trim Line where the vehicle is equipped with its various

components, including chassis, engine, wheels, seats, suspensions, etc.

The GMI manufacturing has in it three major shops as follows:

 BODY SHOP:-
Major activity carried out in body shop is the welding of all the press components

and assembling it to form the car body as per specified model. The maintenance

team 1 is responsible for this area. This team is split into two groups which work

alternatively in A and B shifts under leadership of team leader and assistant team

leader respectively. Major equipments in this area are Weld Transformers,

Weld Guns, Fixtures, Sealer Pumps, Stud welders, Projection welders, Mig welders,

etc.

 PAINT SHOP:-
The paint shop is further divided into Body Paint shop and Plastic paint shop. The

output from the Body shop comes to the Body paint shop and after the paint job is

completed, the painted car body is transferred to the Assembly shop for

final assembly. Major areas or booths in Paint Shop are Pre Treatment plant,

electro dip
plant, electro coat oven, spray booths, prima and topcoat oven, paint shop

ventilators, body-carrying trucks, PT-Elpo conveyors and spray-booth. The

Plastic parts like Bumpers are painted in the Plastic Paint shop and once the paint

job is completed it is send to the Assembly line for final assembly. The Major

equipments in the plastic paint shop are Flaming Zone, Spray Booth and

Humidifier; Sludge handling system, Oven and plant ventilation. Maintenance Team

4 is responsible for this area.

 ASSEMBLY SHOP:-
This is the last activity of the Production where the car is completely assembled.

The major areas in the Assembly shop are Trim Line, Chassis Line, Car Final and

Final Process. Currently two lines are running parallel to each other. One is T&J

line producing Optra, Aveo, UVA and Spark under the brand name of Chevrolet &

second one is I-163 line producing Tavera under the brand name of Chevrolet.
 CHAPTER V

 Testing Of Raw Materials:-

Raw Materials, Services and Supplies We purchase a wide variety of raw materials,

parts, supplies, energy, freight, transportation and other services from numerous

suppliers to manufacture our products. The raw materials primarily include steel,

aluminum, resins, copper, lead and platinum group metals. We have not

experienced any significant shortages of raw materials and normally do not carry

substantial inventories of such raw materials in excess of levels reasonably required to

meet our production requirements. Costs are expected to remain elevated due to the

price of commodities and the continuing existence of tariffs. In some instances,

we purchase systems, components, parts and supplies from a single source and may

be at an increased risk for supply disruptions. Raw materials analysis requires a wide

range of analytical chemistry expertise. The most common tests performed in a raw

materials laboratory include titrations, loss on drying, Karl Fischer moisture

determination, heavy metals limit tests, and infrared spectrophotometry. Full

monograph testing often requires as many as seven different analytical techniques.

For example, to perform full USP monograph testing for methylparaben, eight

different tests using six analytical techniques ranging from infrared absorption to gas

chromatography are required. Therefore, the most efficient organization of a raw

materials laboratories is by function so that analysts can specialize in specific

techniques. To perform even basic monograph testing, laboratories must

contain a wide spectrum of instrumentation.

 CHAPTER VI

 Quality Policies Of Company:-

GM International Single Administrator provides this document, in order to define the

Policy for Corporate Quality and the related goals and tasks. GM International S.r.l

offers international shipping services on customer’s specific request and stands out as

a cutting-edge company for speed, efficiency and flexibility, thanks to the commitment

and skills of its employees. Therefore GM International S.r.l aims at offering its

customers high quality services, which go beyond the shipment itself and stretch to

full assistance and consultancy in the field of logistics, transportation, delivery, storage

and any services related to custom clearance of foreign goods, including custom and

VAT deposit. Our main goal is to strengthen and develop our position in the market,

through a continuous improvement in our offering, in order to increase customer

satisfaction. Our first task is the creation and maintenance of procedures,

which help our organization in defining clear and efficient operations and

communication processes, so that we are able to check and improve every

stage of our service offering, thus facilitating the achievement of both personal

and company goals. GM International Single Administrator is determined to increase

brand awareness, through crystal-clear communication towards customers, high

professionalism and unmistakable and personal style. Being aware of the

importance and responsibility of what above mentioned and having identified the

organizational solutions within the Company, the Single Administrator of GM

International S.r.l decided to implement and maintain a

Quality Management System accomplishing the ISO 9001: 2015 prescriptions and the

Guidelines on good distribution practice (GDP) of medicinal products for human use

issued on 5th November 2013 (ex art 84, art 85 ter, par 3, EEC Directive 2001/83). The

Company Quality System is also fully integrated with all the other systems within the

Company, such as: AEO certified system for custom compliance; IATA Certified

system for safe air shipment. GDP certified system for shipment and delivery of

pharma products. Given the above, GM International S.r.l aims at constantly improve

its efficiency, services, communication, and skills and above all the motivation

and engagement of its team. Being aware of the importance and responsibility of

what above stated, the Single Administrator of GM International S.r.l is

committed to implementing, maintaining and improving the current Company Quality

System. Quality department ensures the best quality to be delivered to the customers.

Quality department audits vehicles right from body shop until final buyoff of the

vehicle. This department has Global Customer Audit area (GCA) where the vehicle is

being inspected for quality, manufacturing and engineering related faults in front of

their respective dept. director and vice-president. The faults are noted down in a

book and respective actions are then taken.

 CHAPTER VII

 Range Of Products:-

GM (General Motors) is best known as the worlds largest full-line vehicle

manufacturer. As a leader in the transportation business GM has products categoring

to about every transportation need. What cars does GM make? Who does GM own?

Among the General Motors brands are Chevrolet, Buick, Cadillac, and GMC. GM makes

all kinds of vehicles, from GM sports cars, SUVs, and smaller cars as well.

 These Products Include:-

 Cars, Trucks, Vans, Buses And Sport Utilities

 Locomotives, Diesel Engines, And Gas Turbines

 Heavy Duty Automatic Transmissions

 Defense Equipment

 Financial Products

 Information Management And Communication

> Ventilators In Recent Covid19 Crisis

 General Motors features several popular vehicle models, including:-

> Hummer H2:- This pick-up truck offers an extendable box that can reach a length

of 6 feet. The cab has room for 6 or 7 passengers.

> Pontiac GTO:- Available from 1964 to 1974, this was widely considered to be the

first muscle car, heralding a trend that resulted in numerous

competitors.
> Chevrolet Volt:- The Volt is a plug-in hybrid introduced in the US in December

2010. GM has sold 73,000 Volts since the model's introduction.

> Cadillac Escalade:- Cadillac's first SUV, this luxury model was first introduced for

the 1999 model year in response to similar luxury SUVs.

> Corvette Stingray Racer:- This concept car was produced in 1957 to serve as the

basis for the second-generation Corvette Stingray.

> Chevrolet Camaro:- The iconic Camaro has been classified as both a pony car

and a muscle car. It was designed for the 1967 model year to compete with the

Ford Mustang.

> Pontiac Aztek:- This mid-size four-door crossover with four-wheel drive and a

four-speed transmission was manufactured from the 2001 model year through

2005.

> Cadillac CTS:- This mid-size luxury sedan was introduced in 2002. It's currently

available as a four-door sedan, two-door coupe, or five-door sport

wagon.

> Hummer H3:- This SUV is the smallest Hummer in the line, and the only one built

by GM.

> Chevrolet Chevette:- Available in both three-door and five-door styles, this

subcompact car was made for model years 1976 through 1987.
 CHAPTER VIII

 Mission Of General Motors:-

General Motors Mission Statement:-

"G.M. is a multinational corporation engaged in socially responsible operations,

worldwide. It is dedicated to provide products and services of such quality that our

customers will receive superior value while our employees and business partners will

share in our success and our stock-holders will receive a sustained superior return on

their investment." The statement inclines towards the experience General Motors can

have on anyone the company interacts with. It has the following components:

> Distinguished services

> Improving communities

In the motor vehicle industry, there is no room for laxity. General Motors understands

that competition is stiff and that customers go for nothing but the best brands. To

satisfy this need, General Motors ensures that it is abreast with the latest

technological advancements, and incorporates these to its designs. In this way, it has

been offering its customers products and services they can get nowhere else.

Additionally, General Motors do more than design cars and related products. The

company extends its benefits to the society not only by designing sustainable sensitive

cars but also by building healthy communities.

 Vision Of General Motors:-
General Motors Vision Statement:-

General Motors’ vision statement is “to create a future of zero crashes, zero emissions,

and zero congestion, and we have committed ourselves to leading the way toward this

future.” The statement has the following elements:

> Create a future

> Leading the way towards this future

In the first element, General motors take up the responsibility of stimulating

innovations that favor future success in the motor vehicle industry through its diverse

and highly creative team of experts. The second component relates to the first one in

that the company also takes up the mandate of leadership to show the way and how

to exploit innovations for the holistic growth of the sector. GM’s vision

statement, unlike its mission statement, alludes to it being a vehicle manufacturer

that takes responsibility for building a safer, better future. “…zero crashes, zero

emissions, and zero congestion” to us, it feels as though the company is alluding to its

ongoing R&D to build better and safer vehicles. However, the company is investing

heavily in green technology, which has next to no emissions.

 CHAPTER IX

 Expansion Of General Motors:-

 GMC - Corporate Affairs (Detroit).

 NAO - North America Operations.

 Vehicle Sales, Service, & Marketing Group - Warren Michigan, Midsize and

Luxury Car Group - Los Angeles, California + Mexico & Canada sales offices.

 LAO - Latin America Operations Brazil, Argentina.

 GME - General Motors Europe,

Poland, Germany, Egypt, South Africa, Hungary, Czech Republic.

 APO - Asia Pacific Operations,

Indonesia, Japan, China & Hong Kong, Philippines,

India, Australia,Malaysia, South Korea, Thailand.

 CHAPTER X

 Turnover Of General Motors:-

General Motors Annual Revenue (Millions of US $):-

 2019 $137,237

 2018 $147,049

 2017 $145,588

 2016 $149,184

 2015 $135,725

 2014 $155,929

 2013 $155,427

 2012 $152,256

 2011 $150,276

 2010 $135,592

 2009 $104,589

 2008 $148,979
 CHAPTER XI

 Future Plans Of GM:-

Now that it has become evident the future for the automotive industry is electric, auto

companies are betting big on electrification. General Motors recently that it will have

20 all-electric vehicles to offer by 2023. As for near future, the biggest automobile

company in the United States plans to introduce two electric cars in coming 18

months. Known for its performance and sports utility vehicles, General Motors is also

looking at a catalogue of battery-operated vehicles and hydrogen fuel-cell cars, which

also run on electricity, stated a Bloomberg report. The profits from GM's SUV

line-up will be reportedly used to fuel company's shift towards zero-emission

vehicles. Mirroring the global auto scenario, Indian car markets have also decided to

go electric. Even though General Motors has already decided to close shop here, there

is no dearth of players. Market leader Maruti Suzuki has planned to produce electric

cars at its Gujarat plant for supplying both Indian and world markets. Another

Indian auto giant, Tata Motors, bagged Rs 1120 crore bid to supply 10,000 electric

cars that will replace the fossil fuel- driven government vehicles. Mahindra and

Mahindra, which has been present in the electric segment for long now, has

disclosed plans to launch electric variants of its flagship SUVs Scorpio and XUV500.

The Indian car maker has even signed an agreement with Ford Motors, of which

electrification is a crucial aspect. General Motors even showcased the upcoming

version of its electrically powered sedan Volt, alongside other concept cars based on

its Buick and Cadillac brands in Detroit yesterday.

The event included a utility vehicle concept that uses fuel cells and two electric

motors, named Silent Utility Rover Universal Superstructure or SURUS. In a market

still dominated by engine-powered vehicles, General Motors is committed to an all-

electric future. The Chevrolet Bolt EV is just a start, as the company prepares

to launch a number of all-electric models in the next several years. The team is

repositioning a 110- year-old company from one of massive scale, industrial might and

market coverage into a nimble, technology-driven mobility company intent on

reinventing personal transportation as we know it. All with the vision of creating a

world with Zero Crashes, Zero Emissions and Zero Congestion. The company plans to

be present in every market segment. GM will soon roll out the small car, Chevrolet

Spark (the relaunched version of Daewoo’s Matiz). The company is also conducting a

due diligence on Daewoo Motors India Limited and, as per plans, Chevrolet Spark will

be rolled out from the company’s Surajpur facility near Delhi.

 CHAPTER XII

 Milestones Of General Motors :-

GM recently reached a significant milestone: 500 million vehicles built globally under

our brands Chevrolet, Cadillac, Opel, Wuling and others. Within that exclusive

500- million production milestone are dozens of innovations that have improved our

customers’ lives and changed the face of the automotive industry.

 1964: 100 Million in Worldwide Production

 1978: 200 Million in Worldwide Production

 1991: 300 Million in Worldwide Production

 2003: 400 Million in Worldwide Production

1901: Ransom Olds’ famous Curved Dash Oldsmobile, designed with simplicity,

reliability and value in mind, was the first American car built in a factory designed

specifically for automobiles and in standardized volume production. GM acquired

Oldsmobile in 1908.

1908: Cadillac wins the Dewar Trophy, Europe’s most prestigious award for precision

and excellence in manufacturing, by demonstrating the auto industry’s

highest standards for precision and interchangeability of parts by disassembling three

Cadillacs and mixing the parts randomly before reassembling and driving them before

a contingent of judges.
1961: The world’s first industrial robot is used at GM’s Ternstedt components plant in

Trenton, N.J. The Unimate’s 4,000-pound arm positions extremely hot diecast

metal parts into cooling pools.

1969: The world’s first programmable logic controller (PLC) application occurs at the

Hydra-Matic Transmission plant in Ypsilanti, Mich. This digital controller was used to

automotive machinery on assembly lines, replacing the labor-intensive use of relays.

1966: Lordstown (Ohio) Assembly opens, and is touted as the most automated

automotive plant in the world.

1980: GM unveils a standardized computer language called Manufacturing Automation

Protocol (MAP) to communicate with PLCs, robots, conveyors and other plant-

floor equipment. Within two years GM Truck and Bus in Pontiac, Mich. truck begins

installing MAP. The result is better control over the manufacturing process because

proprietary data systems are eliminated.

2005: GM operates three of the top five vehicle assembly plants in the annual Harbour

Report. The Oshawa, Ontario, plant is ranked the most productive plant in North America.
 PROCESS: QUALITY CONTROL

 Definition Of Quality Control:-

Quality is a relative concept. It is related to certain predetermined characteristics

such as shape, dimensions, composition, finish, colour, weight, etc. In simple words,

quality is the performance of the product as per the commitment made by the

producer to the consumer. J. M. Juran (1970) who is considered the father of quality

research has defined quality as “the performance of the product as per the

commitment made by the producer to the consumer.”

 There are two main elements in this definition of quality:-

 First, the commitment may be explicit such as a written contract or it may be

implied in terms of the expectations of the average consumer of the product.

 Second, the performance of the product relates to the ultimate functions

and services which the final product must give to the final consumer.

For example, a watch should show accurate time or a ball point pen should write

legibly on a piece of paper. According to ISO 8402: Quality is the “The totality of

features and characteristics of a product or service that on its ability to satisfy stated

or implied needs.” In practice, when we say any product as a quality product, it means

the product satisfies certain criteria for its functioning. For a quality product, it is

necessary that it should satisfy the laid down criteria not only at the time of its

manufacture, but also over a reasonable length of time. In India, Bureau of Indian

Standards lays down certain criteria for a number of products both industrial and
domestic.
Quality control is also a strategic decision. It can be defined as the systematic control

of those variables which are encountered in the manufacturing process and which

adversely affect the excellence of the final product in one way or other.

 Alfort and Beaty defined quality control as:-

“Quality control is the mechanism by which products are made to measure up to the

specifications determined from the customer’s demands and transform into

sales, engineering and manufacturing requirements. It is concerned with making things

right rather than discovering and rejecting those made wrong. Quality control is a

technique by means of which products of uniform acceptable quality are

manufactured.”

 Quality control (QC) is a process by which entities review the quality of all factors

involved in production. ISO 9000 defines quality control as "A part of quality

management focused on fulfilling quality requirements".

This approach places emphasis on three aspects (enshrined in standards such as ISO

9001):-

 Elements such as controls, job management, defined and well managed processes,

performance and integrity criteria, and identification of records

 Competence, such as knowledge, skills, experience, and qualifications

• Soft elements, such as personnel, integrity, confidence, organizational culture,

motivation, team spirit, and quality relationships.

 The quality of the outputs is at risk if any of these three aspects is deficient in
any way.
 History And Introduction

 Quality Control In Early Times:-

Early stone tools such as anvils had no holes and were not designed as interchangeable

parts. Mass production established processes for the creation of parts and system with

identical dimensions and design, but these processes are not uniform and hence some

customers were unsatisfied with the result. Quality control separates the act of

testing products to uncover defects from the decision to allow or deny product

release, which may be determined by fiscal constraints. For contract work,

particularly work awarded by government agencies, quality control issues are

among the top reasons for not renewing a contract. The simplest form of quality

control was a sketch of the desired item. If the sketch did not match the item, it

was rejected, in a simple Go/no go procedure. However, manufacturers soon found

it was difficult and costly to make parts be exactly like their depiction; hence

around 1840 tolerance limits were introduced, wherein a design would function if

its parts were measured to be within the limits. Quality was thus precisely defined

using devices such as plug gauges and ring gauges. However, this did not address the

problem of defective items; recycling or disposing of the waste adds to the cost of

production, as does trying to reduce the defect rate. Various methods have been

proposed to prioritize quality control issues and determine whether to leave them

unaddressed or use quality assurance techniques to improve and stabilize production.

 Methods Or Tools Of Quality Control

Any variations in the quality of a product, i.e., standards set are mainly caused

by variations in raw material, men, machines, methods, and procedures of procedures

of production and inspection. In order to produce the quality products, these

variations need to be checked and controlled.

There are mainly two methods of quality control:-

 Inspection:-

Inspection, in fact, is the common method used for quality control purposes not only in

production but also in services.

As regards inspection in production, there are three important aspects involved in it:-

 Product Inspection:-

As the name itself suggests, the product inspec tion relates to the final product sent

into the market. The main purpose of product inspection is to ensure that the

products sent into the mar ket comply with the set standard for quality. In other

words, it is to ensure that the product ready for sale is perfect and free of defects.

 Process Inspection:-

Process inspection proceeds to product inspection. It is aimed at ensuring that the raw

material and machines and equipment’s used in the production process are of

prescribed quality and mark.

Process inspection benefits the unit in two ways:-

 It ensures the manufacturing of a quality product.

 It saves wastages of material by preventing process bottlenecks.

 Inspection Analysis:-

This is a method based on the analyses of inspections made. The conclusions derived

from the inspection analyses help the entrepreneur locate the exact points in

manufacturing process where faults lie. In other words, it enables the entrepreneur to

identify the points at which deviations from standard set start. Quality control

through Inspection Method is shown in the following Figure.

Quality Control Through Inspection

 Statistical Quality Control:-

It is an advanced method or technique used to control the quality of a product. This

method is based on statistical techniques to determine and control the quality.

Sampling, probability, and other statistical inferences are used in this method

for controlling the quality of a product. It is widely used in process control in

continuous process industries and in industries producing goods on a mass scale.

Under this method, the entire lot is, firstly sampled on the basis of its specific

characteristics and, then, is divided into three parts as mentioned below:-

 Analysis of Samples.

 Use of Control Charts.

 Corrective Measures.

A brief description about each of these follows:

 Analysis of Samples:-

This is based on sampling techniques. First of all, the universe i.e., the population to

be analysed, is identified. After this, following the sampling technique, the

sample representing the whole population is selected and analysed. It is important

that we do not need to analyse all the units of the population, but only a few units

called ‘sample units’ are studied and analysed. The result drawn from these sample

units are then generalized as a whole. In other words, inspection of samples

means statistical inspection of the whole manufactured lot.

 Use of Control Chart:-

Realizing that figures/ charts are always welcome to depict the fact of findings, the

results obtained from analysis of samples are presented in a chart.

The method to draw a chart is as follows:-

 Measure the quality characteristics of sample selected.

 Find out the mean of the sample and also measure its range of dispersion.
 Then, data regarding mean and dispersion are gathered.

 Take a graph paper and plot the gathered data on it.

 Thus, you have a control chart ready to guide you about the quality deviation of

your product.

The shape of the control chart so plotted will be like as follows:-

Quality Control Chart

 Corrective Measures:-

Having drawn quality control chart, the entrepreneur can easily and clearly locate the

points of deviations and causes of it. This enables him to evolve corrective measures

to control the quality of the product accordingly. For example, if variation in quality

is caused by inferior quality raw material, the quality of raw material will be

increased. Similarly, in case of traditional machinery, new and modem machinery will

be installed.
 Quality Control In Manufacturing

In manufacturing, quality control is a process that ensures customers receive products

free from defects and meet their needs. When done the wrong way, it can put

consumers at risk. For example, the recent defect found in Takata airbags resulted in

the biggest automotive recall in history. The recall includes almost 69 million airbag

inflators and may cost billions of dollars. The recall will last until the end of 2019 and

take until 2020 to resolve. Major recalls like these can be prevented through effective

quality control in manufacturing.

Some common tools used to support quality control include:-

> Statistical process control (SPC):-

Monitors and controls quality by tracking production metrics. It helps quality managers

identify and solve problems before products leave the facility.

> Six Sigma:-

Uses five key principles to ensure products meet customers’ needs and have zero

defects.

When supported by lean tools like Total Productive Maintenance (TPM), 5S, and

Kaizen, most if not all defects can be eliminated.

 Benefits of Using Quality Control in Manufacturing:-
 Customers expect and demand high-quality products. When customers receive

quality products you will:-

• Increase customer loyalty.

• Gain repeat business.

• Gain new customers from referrals.

• Maintain or improve your position in the market.

• Improve safety.

• Reduce liability risks.

• Contribute to overall positive branding of your product.

Manufacturers with quality control procedures in place are far less likely to face

product recalls or place customers at risk from poorly made products. The cost

associated with these recalls can be steep. Testament to this is the Takata recall,

which is estimated to cost the company between $7 and $24 billion. Discover how you

can avoid costly recalls and support your quality control system with TPM.

Graphic Products’ Best Practice Guide to Total Productive Maintenance (TPM) will

help you on the road to total quality. Improve quality, eliminate defects, and increase

your profits.
 Incorrect Implementation of Quality Control in Manufacturing:-

Quality control in manufacturing can be a little tricky. Often, it is done at the end of the

production process, only catching defects after the fact.

Effective quality control is more involved and should include two levels:-

> Operators monitor the manufacturing process and ensure that there is little variation.

> Engineers routinely monitor the product design for issues. When a problem is

found, it is immediately fixed.

By monitoring products at the end of production as well as reviewing the products

design, companies can solve problems more efficiently, saving time and money.

 How to Implement Quality Control in Manufacturing:-

To implement an effective quality control program, first create and document your

approach to quality control. This includes:-

 Defining the quality standards for each product

 Selecting the quality control method

 Defining the number of products/batch that will be tested

 Creating and training employees for quality control

 Creating a communication system for reporting defects or potential issues.

 Quality Control in Small-Scale Industries

Although quality control is necessary for all units, yet it is more necessary for small-

scale units. This is because of the great use of manpower in small-scale industries

during the manufacturing processes. But, the application of quality control is difficult

in them because of several limitations like financial, technical and managerial.

Quality implementation is total organizational effort. The successful implementation

of quality control largely depends upon the quality of raw materials, selection of

machinery and equipment, designing, manufacturing, processes, etc. Besides, the

timely and required assistance from the Government organizations, associations,

and institutes also contribute to successful implementation of quality control. In

India, Bureau of Indian Standards (BIS) has been doing a yeoman job in determining

the quality of a large number of products by laying down various criteria for them.

The quality control in small-scale industries is generally based on:

> Indian Standards specification.

> Quality marketing schemes.

> Company Standards in case of ancillary units.

> Any other standard specification prescribed by the Government or other

purchasing agencies.

The Indian Standards Specifications have been playing an important role in persuading

small-scale industries to adhere to the quality of their products.

For controlling quality of products manufactured by small units, the following Indian

Standards have been published so far:-

> Methods of statistical quality control during the production period.

> Manual on basic principles of lot sampling; and

> Sampling inspection table.

Several State Governments have been operating quality marketing schemes and

standards for various products of small-scale industries. When the small units

manufacture their products according to the standards set, the Quality

Marketing Centers of the Government stamp the “Q” mark on their products. This is

an assurance for the customers that the product has been manufactured adhering to

certain quality standards.

 Quality Control of Export Production:-

Implementation of quality control has been very useful in raising exports from an

economy. A product can be sold in foreign markets only when it is not only cheaper

but up to a certain quality also. Standardization of these products convinces the

foreign customers better than any sales campaign. Realising this fact, the Government

of India has made the inspection of several products manufactured by small-scale

industries compulsory before they are shipped abroad. This has proved very beneficial

for the Indian exporters to sell their products in highly competitive foreign markets.
 Importance Of Quality Control

Quality is an important factor when it comes to any product or service. With the high

market competition, quality has become the market differentiator for almost all

products and services. Quality control is essential to building a successful business

that delivers products that meet or exceed customers’ expectations. It also forms the

basis of an efficient business that minimizes waste and operates at high levels of

productivity. A quality control system based on a recognized standard, such as ISO

9001 published by the International Organization for Standardization, provides a

strong foundation for achieving a wide range of marketing and operational benefits.

Therefore, all manufacturers and service providers out there constantly look for

enhancing their product or the service quality. In order to maintain or enhance the

quality of the offerings, manufacturers use two techniques, quality control and

quality assurance. These two practices make sure that the end product or the service

meets the quality requirements and standards defined for the product or the service.

There are many methods followed by organizations to achieve and maintain required

level of quality. Some organizations believe in the concepts of Total Quality

Management (TQM) and some others believe in internal and external standards. The

standards usually define the processes and procedure for organizational activities and

assist to maintain the quality in every aspect of organizational functioning. When it

comes to standards for quality, there are many. ISO (International Standards

Organization) is one of the prominent bodies for defining quality standards for

different industries. Therefore, many organizations try to adhere to the quality

requirements of ISO.
In addition to that, there are many other standards that are specific to various

industries. Since standards have become a symbol for products and service quality,

the customers are now keen on buying their product or the service from a certified

manufacturer or a service provider. Therefore, complying with standards such as ISO

has become a necessity when it comes to attracting the customers. Every organization

that practices QC needs to have a Quality Manual. The quality manual outlines the

quality focus and the objectives in the organization. The quality manual gives the

quality guidance to different departments and functions. Therefore, everyone in the

organization needs to be aware of his or her responsibilities mentioned in the quality

manual.

Some of the important advantages to quality control are as follows:-

> The brand products build up goodwill or image which ultimately increases sales.

> It helps the manufacturers/ entrepreneurs in fixing responsibility of workers in the

production process.

> Quality control also helps in minimizing the costs by increasing

efficiency, standardization, working conditions, etc.

> It also enables the entrepreneur to know the cost of his / her product quite in

advance which helps him in determining competitive prices of his product.

> Last but not the least; the entrepreneur can confirm whether the

product manufactured by him / her is in accordance with the standard set by the

Government.
 Quality Control, QA and Lean Manufacturing

Lean manufacturing tools can bolster your company’s quality program. Lean revolves

around improving quality and safety while increasing efficiency and profits.

Some powerful lean manufacturing tools that can bolster your quality system include:-

> TPM improves product quality by eliminating downtime, defects, and accidents.

TPM accomplishes this through comprehensive maintenance programs and

operator training.

> Kaizen helps eliminate problems at their source by empowering workers to find

and solve problems on a daily basis.

> 5S helps organize and standardize the workplace. Take control with the 5S System

Best Practice Guide, by Graphic Products. Improve procedures and eliminate errors

in your facility.
 The Techniques Of Quality Control

> There are several methods of measuring the performance of quality control. A

quality control chart is a graphic that depicts whether sampled products or

processes are meeting their intended specifications—and, if not, the degree by

which they vary from those specifications. When each chart analyzes a specific

attribute of the product it is called a univariate chart. When a chart measures

variances in several product attributes, it is called a multivariate chart.

> Randomly selected products are tested for the given attribute or attributes the

chart is tracking. A common form of a quality control chart is the X-Bar Chart,

where the y- axis on the chart tracks the degree to which the variance of the

tested attribute is acceptable. The x-axis tracks the samples tested. Analyzing the

pattern of variance depicted by a quality control chart can help determine if

defects are occurring randomly or systematically.

> The Taguchi Method of quality control is another approach that emphasizes the

roles of research and development, product design, and product development

in reducing the occurrence of defects and failures in products. The Taguchi Method

considers design to be more important than the manufacturing process in quality

control and tries to eliminate variances in production before they can occur.
 The Role of Quality Control Inspectors

A Quality Control Inspector checks the quality of incoming and outgoing products for a

company by conducting tests, monitoring production processes and

identifying malfunctions. They work in various manufacturing and production settings,

such as the quality control department, assembly lines and laboratories. These

professionals examine quality standards in the manufacturing stage of products like

foods, motor vehicles, electronics, textiles and clothing. Quality Control Inspectors

ensures products meet their company’s quality standards and are safe for

consumers to use. Quality control inspectors protect the consumer from defective

products and the company from damage to its reputation due to inferior

manufacturing processes. If the testing process reveals issues with the product,

the inspector has the option of fixing the problem himself, returning the product

for repairs or tagging the product for rejection. When issues arise, the inspector

notifies supervisors and works with them to correct the problem. A Quality Control

Inspector performs assessment, documentation and organization tasks to support

the efficiency and effectiveness of their organization’s supply chain. These workers

monitor quality standards for nearly all manufactured products, including foods,

textiles, clothing, glassware, motor vehicles, electronic components, computers,

and structural steel. Specific job duties vary across the wide range of industries in

which these inspectors work.

 Cost of Quality Control

Lastly, let us also address to an important aspect of quality control, i.e., cost involved

in ensuring quality products. In fact, it is difficult, if not impossible, to precisely define

cost incurred in quality assurance due to so many imponderables involved. But there

is no denying of the fact that it should be a minor proportion of the total product cost

incurred. How much minimum should be the proportion of quality cost to total cost

depends upon various factors?

Some of the important ones are:-

> Type of product, its functional use and hazards involved in its use.

> The degree of quality awareness prevailing in the enterprise by implementation

of the concepts like Total Quality Management (TQM) and Quality Control (QC).

> Lastly, additional costs to be incurred for ensuring higher quality standards. It

must be kept in mind that there is no optimum value between quality and

product cost.