Subject: Metallurgical Plants and Quality Control

Course code: MY – 409

Course teacher: Dr. Iftikhar Ahmed Channa

Quality Management System

Department of Metallurgical Engineering

NED University of Engineering and Technology
 Introduction
Introduction
Introduction Contents of Lecture

•
Motivation &
QMS
Energy sources
Targets Introduction
• Definition
EnergyTheoretical
role QMS
Understanding
Background
• Purpose
• QMS
Forms
QA of
vsEnergy
QC
Approach I
• Understanding the QMS
• QA vs QC
• QA Techniques
Energy
QA &
Approach II
Environment
Techniques • QC Techniques

Energy in Metallurgical
QC Techniques
Summary
Summary
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 Introduction
Introduction
Introduction Introduction
Organization Personnel Equipment

Motivation &
QMS
Targets

Purchasing Process Information

& Management
Understanding QMS
Theoretical
Background
Quality management Inventory
Control

system involves
several steps
QA vsApproach
QC Documents
I Occurrence
& Assessment
Management
Records

QA
Approach II
Techniques
Process Customer Facilities
Improvement Service &
Safety
QC Techniques
Summary
Summary
& outlook
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 Introduction
Introduction
Introduction Definition

QMSMotivation &
Energy sources
Targets
Quality Control (QC) is part of quality management
focused on fulfilling quality requirements ISO 9000:2000
EnergyTheoretical
role QMS
Understanding
Background
(3.4.10)

Forms
QC is examining “control” materials of known
QA of
vsEnergy
QC
Approach I
substances along with samples to monitor the accuracy
and precision of the complete examination (analytic)
Energy
QA &
process.
Approach II
Environment
Techniques

Energy in Metallurgical
QC Techniques
Summary
Summary
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 Introduction
Introduction
Introduction
Introduction Purpose

QMSMotivation &
Energy sources
Targets

The goal of management system

Inks &
Droplets

is to detect errors/ faults /

EnergyTheoretical
role QMS
Understanding
Background

Printed Layers

Forms
QA of
& Cells

vsEnergy
QC
Approach I
shortcomings in the process and
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product and correct them before
the results are reported
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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QC Techniques
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 Introduction
Quality management system steps
Introduction
Introduction
Introduction

Establish
written include
Motivation &
corrective
QMS
Energy sources
Targets policies and
Inks &
Droplets
procedures actions
EnergyTheoretical
role QMS
Understanding
Background

Printed Layers
& Cells
Review QC Program Train
QC data all staff
Steps
Forms
QA of
vsEnergy
QC
Approach I

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Modules
Energy
QA &
Approach II
Environment
Techniques
Assure
complete
Summary documentation
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 Introduction
Introduction
Introduction
Introduction Understanding Quality Management

QMS
Energy
Motivation &
sources
Targets
Inks &
Quality assurance
Droplets

EnergyTheoretical
role QMS
Understanding
Quality planning
Background

Printed Layers
& Cells
Quality control
Forms
QA of
vsEnergy
QC

Quality improvement
Approach I

Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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doi:10.1016/b978-0-08-096988-6.00034-1 
 Introduction
Introduction
Introduction
Introduction Understanding Quality Management
Quality Assurance, is a planned and systematic way of creating an
QMS
Energy
Motivation &
sources
environment to assure that the product being developed meets the
quality requirements.
Targets
Inks &
Droplets

EnergyTheoretical
role QMS
Understanding
QA refers to the implementation of well-defined standard practices
Background and methods. It is a pro-active quality process.
Printed Layers
& Cells

Forms
This process is controlled and determined at managerial level.
QA of
vsEnergy
QC
Approach I

Quality assurance focuses on the process checklists, process

standards, project audits, methodology and procedures for
Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques
development.
It is a preventive process that aims at establishing the correct
Energy
Summary
& Outlook
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methodology and standards to provide a quality conducive
QC Techniques
Summary
&
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 Introduction
Introduction
Introduction
Introduction Understanding Quality Management

Motivation &
Quality Planning
QMS
Energy sources
Targets
Inks &
Droplets In this sub process, quality assurance plan is created for a particular
project. In the quality assurance plan, organizational standards are
selected which are applicable to a project. It should also involve the
EnergyTheoretical
role QMS
Understanding
Background

Printed Layers plan for quality control.

& Cells

Forms
QA of
vsEnergy
QC
Approach I Quality assurance planning details out what QC activities are
performed, when the QC activities are performed and who will
Printed Solar
Modules
perform those. It also contains details of resource required, tools
Energy
QA &
Approach II
Environment
and techniques to be used for performing quality control.
Techniques

Summary
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 Introduction
Introduction
Introduction
Introduction Understanding Quality Management
Quality Control is the set of activities that control the quality of
QMS
Energy
Motivation &
sources
product being developed by identifying any bugs that might be
Targets
Inks & present.
Droplets

EnergyTheoretical
role QMS
Understanding
It is a subset that falls under the quality assurance. It is a corrective
Background process.
Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
After fixes, the product is verified again such that the functionalities
and features are working as required.
Approach I

Printed Solar
QC process assures that that the product being developed is of the
Modules required quality.
Energy
QA &
Approach II
Environment
Techniques
Examples of quality control activities include inspection, deliverable
Summary peer reviews and the software testing process.
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 Introduction
Introduction
Introduction
Introduction Understanding Quality Management

QMS
Energy
Motivation &
sources
Targets
Quality Improvement
Inks &
Droplets
Quality improvement is a formal approach to analyse the feedback
EnergyTheoretical
role QMS
Understanding received from the quality control team.
Background

In this process efforts are put systematically to identify any room of

Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
Approach I
improvements in the existing standards and procedures.

Printed Solar The target is to improve the process that establish the standards of
Energy
QA &
Modules
quality in the organization.
Approach II
Environment
Techniques

Summary
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 Introduction
Introduction
Introduction
Introduction Quality assurance vs Quality Control

Quality Assurance is the set of activities that determine the

QMSMotivation &
Energy sources
Targets
Inks &
Droplets procedures and standards to develop a product
EnergyTheoretical
role QMS
Understanding
Background

Quality Control refers to the activities and techniques to

Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
Approach I
verify that the developed product is in conformance with the
requirements.
Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques The ultimate output of both processes is to deliver a quality
product.
Summary
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 Quality assurance vs Quality control
Introduction
Introduction
Introduction
Introduction
Quality Assurance Quality Control
Definition QA is the implementation of QC is the set of activities that are
processes, methodologies and carried out to verify the developed
QMSMotivation &
Energy sources
Targets standards that ensure the quality product meets the required
Inks & standards. standards.
Droplets

Target QA focuses on the improvement of QC focuses on the improvement of

EnergyTheoretical
role QMS
Understanding process and methodologies used to the product by identifying the
Background develop product. errors/defects and issues.
Printed Layers
Orientation It is process oriented. It is product oriented
& Cells

Forms
QA of
vsEnergy
QC
Nature of QA is preventive process as it QC is corrective process as it
Approach I
process establishes the methods which focuses on identifying the defects
prevent the defects and getting them fixed.
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Modules
Verification vs Quality Assurance is a verification Quality assurances is a validation
Energy
QA &
Validation activity that verifies you are doing the activity that validates the product
Approach II
Environment
Techniques right thing in the right manner. against the requirements.
Who All the persons involved in the project It is the responsibility of Quality
Summary starting from the requirement. Control inspector or the testing team
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Summary
that finds the issues.
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 Introduction
Introduction
Introduction
Introduction Quality assurance vs Quality control

Quality Assurance Quality Control

Motivation &
QMS
Energy sources
Targets
Tools and Defining Processes, Quality Audit, Defining Processes, Quality Audit,
Inks & Techniques Selection of Tools, Training. Selection of Tools, Training
Droplets
Examples Examples of quality assurance Examples of quality control activities
activities include process checklists, include inspection, deliverable peer
EnergyTheoretical
role QMS
Understanding
Background
process standards, process reviews and the software testing
documentation and project audit. process.
Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
Approach I

Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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QC Techniques
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques

It is critical that the organizational standards are defined by experts

QMS
Energy
Motivation &
sources as it will lay the foundation of quality assurance and assures
development of reliable, quality products.
Targets
Inks &
Droplets

The standard is harmonized with the material life cycle process and
EnergyTheoretical
role QMS
Understanding
Background

Printed Layers contains requirements for initiating, planning, controlling and

& Cells
executing the Quality Assurance.
Forms
QA of
vsEnergy
QC
Approach I

Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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QC Techniques
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques

Quality Audit
QMSMotivation &
Energy sources

Quality audit is a quality assurance technique that examines the

Targets
Inks &
Droplets
work products and evaluate whether the product has followed the
EnergyTheoretical
role QMS
Understanding standards, guidelines, regulations, plans and procedures.
Background

Printed Layers
& Cells
It a systematic approach to examine all the required procedures
Forms
QA of
vsEnergy
QC
Approach I
and standards were considered at the time of product
development and testing.
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Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques

Selection of tools
QMSMotivation &
Energy sources
Targets
Inks & 1. Cost-Benefit Analysis
Droplets
Cost benefit analysis is a systematic approach of evaluating an
EnergyTheoretical
role QMS
Understanding investment against its expected benefits. It is used to determine
Background
whether the investment is feasible in terms of labour, time and cost
Printed Layers
& Cells savings.
Forms
QA of
vsEnergy
QC
Approach I
2. Cause and Effect Diagrams
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Modules
Cause and Effect diagram is also known as ‘Fishbone’ or ‘Ishikawa’
Energy
QA &
Approach II
diagram. This technique uses brainstorming with mind mapping on
a diagram and compels you to think of all the possible causes to a
Environment
Techniques

problem. Once you have identified the root cause, you will be able
to find the right solution for it.
Summary
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques
Selection of tools
QMS
Energy
Motivation &
sources
Targets
1. Cost-Benefit Analysis
Inks &
Droplets Cost benefit analysis is a systematic approach of evaluating an
investment against its expected benefits. It is used to determine
EnergyTheoretical
role QMS
Understanding
Background
whether the investment is feasible in terms of labour, time and cost
Printed Layers savings.
& Cells

Forms
QA of
vsEnergy
QC
Approach I

Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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QC Techniques
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques
Selection of tools
QMS
Energy
Motivation &
sources
Targets
1. Cost-Benefit Analysis
Inks &
Droplets Cost benefit analysis is a systematic approach of evaluating an
investment against its expected benefits. It is used to determine
EnergyTheoretical
role QMS
Understanding
Background
whether the investment is feasible in terms of labour, time and cost
Printed Layers savings.
& Cells

Forms
QA of
vsEnergy
QC
Approach I

Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
Energy & Outlook
in Metallurgical
QC Techniques
Summary
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques

QMSMotivation &
Energy sources
Targets
Inks &
Droplets

EnergyTheoretical
role QMS
Understanding
Background

Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
Approach I
2. Cause and Effect Diagrams
Printed Solar
Modules
Cause and Effect diagram is also known as ‘Fishbone’ or ‘Ishikawa’
Energy
QA &
Approach II
diagram. This technique uses brainstorming with mind mapping on
a diagram and compels you to think of all the possible causes to a
Environment
Techniques

problem. Once you have identified the root cause, you will be able
to find the right solution for it.
Summary
Energy & Outlook
in Metallurgical
QC Techniques
Summary
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques
3. Control Charts
Control charts are used to analyse performance trends of process
over time. It is an important tool to determine if you need to make any
QMSMotivation &
Energy sources
Targets
Inks &
Droplets fundamental changes to the process and avoid specific problems.
EnergyTheoretical
role QMS
Understanding
Background

Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
Approach I

Printed Solar
Modules
Energy
QA &
Approach II
Environment
Techniques

Summary
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques

4. Cost of Quality
QMS
Energy
Motivation &
sources
Targets
There can be two types of cost of quality. The cost of poor quality
Inks &
Droplets
affects the internal and external costs resulting from failing to meet
requirements. On the other hand, the cost of good quality includes the
EnergyTheoretical
role QMS
Understanding prevention costs for investing in services and appraisal of product.
Background

Printed Layers
& Cells

5. Benchmarking
Forms
QA of
vsEnergy
QC
Approach I

Benchmarking is the process of measuring performance to standard

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Modules
metrics and practices.
Energy
QA &
Approach II
Environment
Techniques

Summary
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 Introduction
Introduction
Introduction
Introduction
Quality Assurance Techniques

6. Design of Experiments
QMS
Energy
Motivation &
sources It is systematic approach carried
under controlled conditions to
Targets
Inks &

determine the relationship between

Droplets

EnergyTheoretical
role QMS
Understanding factors affecting a process and the
Background
output of the process.
Printed Layers
& Cells

Forms
QA of
vsEnergy
QC
It is used to manage process in
Approach I
order to analyse which input has the
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significant impact and what steps
Energy
Modules can be taken to optimize the output.
QA &
Approach II
Environment
Techniques

Quality Culture
Summary
Energy in & Outlook
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Summary
Summary
A quality culture should be established where everyone feels
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Thank you for your attention!

Department of Metallurgical Engineering

NED University of Engineering and Technology