Training On Baisics of Quality

Basics of Quality Assurance
Part -1
Sibaram Das, 2/Jun/2021
Technology Innovation Leadership

CONTENTS
1. Evolution of Quality Control
Operator Quality Control , Foreman Era , Quality Inspector , Control Charts(only concept)
Sampling Plan , Quality Circle , Cause & Effect Diagram (Ishikawa) , Taguchi method
2. Quality
Definition ,What is Non Conformity ,
Attributes of Quality
Quality Characteristics
3. Inspection – Attribute & Variable

Familiarise various basis inspection tools
GO-NOGO,TPG , Scrata, SA 2.5 , Comparator
Thread , Pitch Gauge use, Interpretation
4. Tolerance ,Limit , types of fits , examples
5. Aspects of Quality
Design of Quality , Conformance of Quality , Performance of Quality .
Offline Quality Control
Evolution of Quality – Phase 1
1) Ancient Egyptians – 5th Century B.C – Pyramids , Rome Built

cities , Bridges , temples – Inspire us even today .
2) Middle Age up-to 1800 s

• Production of Goods & services confined to single Individuals
or Groups . Family owned business
• Responsibility of Controlling Quality lay with a person or a
Samll Group.
3) Till 1983 – Phase -I

• Operator Quality Control Period .
• Entire Manufacturing or Service also controlled by Operator
• Volume of Production was limited .
• Pride in workmanship.

Evolution of Quality – Phase 2
4) 1900 to 1920 , Phase – II
• Foreman Quality Control Period

• Industrial Revolution
• Specialisation of labour
• Not one person responsible for entire
work , but only a portion of it.
• Decrease in workers sense of
accomplishment & sense to work.
A supervisor who directed the operation also responsible for

Quality.

Evolution of Quality – Inspector Era
5) 1920 to 1940 ,
• Inspection Quality Control Period

• Volume increased , No.of workers
reporting to Foreman(FM) increased
• Impossible for FM to control
• Therefore Inspector assigned .
• Standards (std.) were set.

• Items Not meeting std. were kept aside .
• NC either Reworked or discarded ( some
cases segregated as of Degraded
category)
Inspector checks Quality of the product after certain operation.

Evolution of Quality – control chart
6) 1924 – WALTER A SHEWHART of Bell telephone
proposed concept of STATISTICAL CHARTS to control
variables of products ,
• Inspection Quality Control Period

• Volume increased , No. of workers reporting to
Foreman(FM) increased
• Impossible for FM to control
• Therefore Inspector assigned .
Statistical Process Control (SPC) = process monitoring

Control Chart = Monitoring Chart

Evolution of Quality – Control Chart

Evolution of Quality – Control Chart

Evolution of Quality – Sampling Plan
a sampling plan is a statistical method of determining whether to accept or reject a lot of material that is being produced.
Sampling plans are used when testing is destructive and all parts would be consumed during testing, leaving no parts for
commercial use or distribution, the cost of 100 percent inspection is very high, or 100 percent inspection takes too
long. Sampling plans are a means of identifying, not preventing, poor quality.

https://www.cqeacademy.com/cqe-body-of-kno
6) 1920 – H F Dodge & H G Romig of Bell telephone wledge/product-process-control/acceptance-sa
Sampling Plan mpling
/
• AQL – Acceptance Quality Level
• Ac- Acceptance Number
• R – Rejection Number Sampling plan followed at our factory:-
QA Sampling Plan
sampling latest standards and plans –
IS 2500 , ISO 2859
2 Risks of sampling Remember, the goal of acceptance sampling is to accept good material, and reject bad material. So,
two of the four outcomes below are correct. Producer and Consumer Risk arises when we make the wrong decision.

AQL In Quality Control Sampling
At Metal Cutting, experience has shown us that inspecting a small portion of the parts in a lot is not only faster and more
cost-effective — it also allows us to pay closer attention to the inspection process. With every piece in the sample being
more carefully inspected, the likelihood of errors or of simply missing something is reduced.
Best of all, a quality sampling plan provides statistically valid results and high confidence that if the sample is defect-free,
the entire lot will meet the customer’s requirements for an Acceptable Quality Level (AQL).
Statistically, AQL is a measure of the maximum number of defective goods that would be considered acceptable in a
particular sample size. It corresponds to the percentage of a production run that can be rejected before some corrective
action must be taken.
The higher the AQL, the fewer the number of parts that will be inspected. This means with a lot size of 100,000 pieces,
for example, 123 pieces would be inspected at AQL 0.4, but only 29 pieces would be inspected at AQL 4.0.
AQL 1.0 c=0, which is a zero acceptance sampling plan

Evolution of Quality – Quality Circle
7) 1950 – W Edwards Deming Visited Japan after World
War II
8) 1960 – Concept of Zero Defect
• Achieving Productivity through workers involvement

. NASA adopted this for manufacturing missiles .
9) 1960 – Quality Circle – Gained in Japan
• Concept based on participation type management .

Productivity improve through uplift of morale &
motivation . Constitution of Sub-groups.
10) 1970 – 1983 – Total Quality Control – Organisation

wide (Feigenbaum)
• Participation of Operator to 1st line supervisor to

Manager , VP & CEO
• Quality associated with every individual

Evolution of Quality – Cause and Effect
Helps in Identify of Possible reasons for a process to go out of control as well as possible effects on the process .
What is a “Cause and Effect Diagram”?

A cause-effect diagram is a visual tool used to logically organize possible causes for a specific problem
• The C-E Diagram is a fundamental tool utilized in the early stages of an improvement team.
• The ideas generated during a brainstorming or affinity process are used to populate the diagram.
• Since the list of issues on a C-E may be very large, the team should use a prioritization or multi-vote technique to narrow the
list of potential cause that they desire to investigate farther.
Cause and Effect Diagram Example: Lost Control of Car Cause & Effect
or

Ishikawa
or
Fishbone

https://www.juran.com/blog/the-ultimate-guide-to-cause-and-effect-diagrams/


Cause and Effect Diagram Key Concepts
A cause-effect diagram cannot identify a root cause; it presents graphically the many causes that might
contribute to the observed effect.
It is a visual representation of the factors that might contribute to an observed effect that is being
examined.
The interrelationships among the possible causal factors are clearly shown. One causal factor may
appear in several places in the diagram.
The interrelationships are generally qualitative and hypothetical.
It focuses the attention of all team members on the specific problem at hand in a structured,
systematic way.

Evolution of Quality – Taguchi method
11) 1970 – 1990 G Taguchi of Japan
• Quality Improvement through Statistically designed experiments .
• ANOVA (Analysis of Variance)
• Example
SCHEMATIC DIAGRAM OF MIG/MAG HYBRID WELDING

27 MACRO EFFECT OF PARAMETERS ON GEOMETRY OF WELD

EFFECT OF PROCESS PARAMETERS ON WELD PENETRATION EFFECT OF PROCESS PARAMETERS
ON WELD BEAD HEIGHT
OPTIMISATION IN RELATION TO
SMALLEST BEAD HEIGHT

Evolution of Quality – Summary
Approximate
Terminology Description
year of first use
Statistical quality control The application of statistical methods (specifically control charts and acceptance sampling) to
1930s
(SQC) quality control[8]:556
Popularized by Armand V. Feigenbaum in a Harvard Business Review article[9] and book of the

Total quality control (TQC) 1956 same name.;[10] stresses involvement of departments in addition to production (e.g.,
accounting, design, finance, human resources, marketing, purchasing, sales)
Statistical process control The use of control charts to monitor an individual industrial process and feed back
1960s
(SPC) performance to the operators responsible for that process; inspired by control systems
Company-wide quality
1968 Japanese-style total quality control.[11]
control (CWQC)
Total quality management Quality movement originating in the United States Department of Defense that uses (in part)
1985 the techniques of statistical quality control to drive continuous organizational improvement
(TQM) [12]
Six Sigma (6σ) 1986 Statistical quality control applied to business strategy; [13] originated by Motorola
Six Sigma applied with the principles of lean manufacturing and/or lean enterprise;

Lean Six Sigma (L6σ) 2001
originated by Wheat et al.[14]

Evolution of Quality – Summary
1960,Gradual 1990 Further

1800 Advanced
Ancient Involvement – Taguchi
1920-1940 approache
Self work, Company wide DOE d
Inspector
small All fnctn, Mngr, VP QMS etc
(attitude of QC IS0 9001
group responsibility of
Inspector& Quality
function alone – is
Changed)
1980
Computer use
QC software's,
1900-1920 Vendor Quality
Forman 1940-1960 1970-1983 Control, Product
Era/Supervisor Statistical Quality Total Quality design assurance,
Control , Control Produut Quality audit
Sampling Plan Organisation wide

(Feigenbaum)
Ishikawa
Quality
Quality
• Crosby 1979.
Quality is conformance to requirements or specifications
• Juran 1974.
Quality is fitness for use
The Quality of a Product or Service is the fitness of that product or service for meeting or exceeding its
intended use as required by the customer

Quality Attributes
Quality
• Gravin, 1984 .
1) Transcendent (to go further than usual limits of something)
2) Product Based
3) User Based
4) Manufacturing based
5) Value Based
8 Attributes of Quality
2.Features 4.Conformance 6.Serviciability 8.Percieved

Quality
1.Performance 3.Reliability 5.Durability 7.Aesthetics

What is a defect?
Is defect & Non conformity are same ?
A defect is associated with a Quality Characteristics that does not meet certain standards.
Furthermore , the severity of one or more defects in a product or service may cause it to be
unacceptable (A Defective)
The Modern term of defect is Non Conformity

Quality Characteristics
1. Structural – Length , Viscosity , Resistance.
2. Sensory – Feel ,appearance .
3. Time oriented – Warranty , Reliability
4. Ethical – Honesty , Curtesy
Characteristics broadly divided into 2 categories
Attribute Variable

Quality Characteristics - Attributes
Attribute
Either conforming or Non conforming
GO - NOGO
https://youtu.be/nfoUdm9WdE4
Understanding of limits ,fits & tolerance .

https://youtu.be/BY2fK-cLW-w

Quality Characteristics - Attributes
Formula
Attribute
Example for Plain Plug Gauge
GO = Nominal size / Lower most size of hole + Wear & tear allowance(Z) + Mfg
allowance
Plug gauge for Hole size = 30.02/30.08 mm

PLUG GO Gauge = 30.02 + 0.012 + 0.0025 = 30.0345 mm
NO-GO = Upper limit +/- Gauge mfg allowance

= 30.08+/- 0.0025 = 30.0825 / 30.0775 mm

Inspection by Gauge – Thread Gauge
Question :- Is the NPT thread checking is done by

TPG ? Is the gauge has both GO & NOGO?
https://www.youtube.com/watch?v=nakVNcHVvwc

Inspection by Gauge – Thread check by wire method
Major mistake
happened in
past & resulted
a Big field
failure
LH thread
made RH https://www.youtube.com/watch?v=LjQf6ISFlSg
https://www.youtube.com/watch?v=vNvJi2culC4
2 WIRE METHOD
3 WIRE METHOD

Inspection by Gauge - SCRATA
1) Casting Surface Quality – SCRATA comparators
ASTM A 802 SCRATA – Comparators for the definition of surface quality of steel castings
https://howshun.com/blog/astm-a-802-scrata/
The nine categories are of surface irregularities are:

A. Surface Roughness – The natural surface of the casting after shot blasting. , B. Surface Inclusions – Non-metallic material trapped on the
casting surface. C. Gas Porosity – Indications of gas at the casting surface. D. Laps and Cold Shuts – Surface irregularities giving a wrinkled
appearance. E. Scabs – Slightly raised surface irregularities. F. Chaplets – Indications of chaplets or internal chills.G. Surface Finish / Thermal
Dressing – Surface remaining after using oxy-gas or air-carbon arc processes for metal removal. H. Surface Finish / Mechanical Dressing –
Surface remaining after using a mechanical means of dressing a cast surface or a previously thermally dressed surface.
J. Welds – Indications of welds fully or partially removed by thermal or mechanical dressing.

Inspection by Gauge - SCRATA
TIL EPS CASTING SCRATA :-
• Unless otherwise specified, surfaces must conform to the following SCRATA requirements:
• Surface Texture - A2
• Non-Metallic Inclusions - B4
• Gas Porosity - C3
• Fusion Discontinuities - D2
• Expansion Discontinuities - E3
• Inserts - Not Allowed
• Thermal Dressing - G2
• Mechanical Dressing - H4
• Metal Removal Marks - J2
Can you :- Abhishek – Please prepare a SCRATA Quality standard with Photographs

Inspection by Gauge – Comparator for Surface finish
What is Ra
What is Rz

Inspection by Gauge – Comparator for Shot Blasted surface

Quality Characteristics – Variables
Standards or specification
A set of conditions and requirements of specific & limited application , that provide a detailed description
of the procedure , process, material, product or service for use primarily in procurement and
manufacturing
Variable
Variable Characteristics
Measurable & are expressed on a numerical scale. 1) Length

2) Viscosity
3) Pressure
4) Resistance
5) Gloss
6) Flatness
7) Pressure

Quality Characteristics – Variables – Tolerance
NOMINAL SIZE : The size used for general description. Example; 7/8 inch Shaft, 25mm Shaft etc.
BASIC SIZE : The size used when the nominal size is converted to the decimal and from which deviation are
made to produce limit dimension. Example: .8750inch shaft which is the basic size for a 7/8 inch nominal
shaft.25mm nominal size which can be basic size of 24.950mm.
LIMIT DIMENSION : The Lower and Upper permitted sizes for a single feature dimension. 0.500-0.506 inch
where 0.500 inch is the lower limit and 0.506 inch upper limit dimensions
TOLERANCE :Tolerance is the allowable variation for any given size in order to achieve a proper function.
Tolerance equals the difference between lower and upper limit dimensions. Example; for 0.500-0.506 inch the
tolerance would be 0.006 inch.
FIT : The general term of fit to describe the range of tightness designed into parts which assemble one into
another. The fit can be explained under the three categories.

BILATERAL TOLERANCE : It is a way to express tolerance by using both minus and plus variations from a
given size. Example;
The limit dimensions are 1.120-1.130 inch. The tolerance is 0.010 inch.
UNILATERAL TOLERANCE : It is a way to express tolerance by using only minus or plus variation from a
given size. Example

BASIC-SHAFT SYSTEM : This is a system
in which the basic size is included as one
of the limit dimensions of the shaft. But
it is not for the hole. As an example: for a
basis size of 1.000 inch. The limit
dimensions on the shaft could be 1.000
and 1.005 inch. The related hole could be
1.011 and 1.018 inch.
BASIC-HOLE SYSTEM : This is a system in

which the basic size appears as one of
the limit dimensions of the hole. But it is
not for the shaft. As an example for a
basic size of 1.000 inch, the limit
dimensions of the hole might be 1.000
and 1.007 inch. For the related shaft the
limit dimensions could be 0.994 and
0.989 inch.
MINIMUM MATERIAL CONDITION : In this condition a hole is at its largest limit dimension. A shaft is at its smallest limit dimension. This condition exists at
maximum clearance or minimum interference.
MAXIMUM MATERIAL CONDITION : In this condition a hole is at its smallest limit dimension. The shaft is at its largest limit dimension. This condition exists at
minimum clearance or maximum interference. See example under the Force fit condition.
Example For Hole

27 types of Fits , 18 Grades
20 Dia H7 - -- >
A,B,C,D , ….. G,H – Hole basis – Capital letter Tol 20+0.0+0.021 ,
20 Dia H8 ---- 20 +0.0 , + 0.033
.a,b,c….. ………..- Shaft Basis – Small letter
Shaft will be
Limit – The largest & smallest 20f6 - 20.00 -0.034 ,-0.016
Tolerance :- Permissible variation 20 h6  20.00 -0.0 -0.017
20.00 +/- 0.01
Limit – 20.01 mm , 19.99 mm

Tolerance – 0.02 mm

A clearance fit. The shaft is always smaller than the hole

Tolerance on shaft : 0.002
Tolerance on hole : 0.002
minimum clearance : 0.600 - 0.595 = 0.005 inch
maximum clearance : 0.602 - 0.593= 0.009 inch
The 0.005 clearance in for the tightest possible fit.

An Force (interference) fit. when the shaft is always larger

in diameter than the hole parts must be assembled by
pressure or heat expansion.
minimum clearance : 0.500 - 0.503= -0.003 in (the tightest
fit 0.003 in interference)
maximum clearance : 0.501 - 0.502 = -0.001 in (the
loosest fit 0.001 in interference)
Maximum clearance=Minimum interference
Minimum clearance=Maximum interference

A transition fit exist when the maximum clearance is

positive and the minimum clearance is negative
minimum clearance : 0.500 - 0.507 = -0.007 inch
The tightest fit is 0.007 in interference.
maximum clearance : 0.505 - 0.002 = 0.503 inch
The loosest fit is 0.003 in clearance
Transition fits are used only for locating a shaft relative to
a hole,
where accuracy is important but either a clearance or
interference is permitted.

Three Aspects of Quality
• Quality of design
• Quality of conformance
• Quality of performance

Quality of Designs
It deals with the stringent conditions that the Product(P) or Service (S) must minimally possesses to satisfy the
requirements of customer.
It implies that the P or S must be designed to meet at least minimally the needs of the consumer .
The design should be simplest and least expensive while still meeting the customer expectations .
Quality of design is influenced by such factors as

• Type of product
• Cost
• Profit policy of company
• Demand for Product
• Availability of parts & materials
• Product safety
Example :- Quality level of Yield strength of steel cable desired by customer is 100Kg/cm2 , when designing such a
cable the parameter that influence the YS should be selected so as to satisfy the requirements at least minimally .
In practice the product is typically overdesigned so that the desire conditions are exceeded .
Thus design with 25% stronger load characteristics , K value 1.25 .

Quality of Designs
In most of the situations the effect of an increase in designed Quality level is to increase the cost at an exponential
rate . The value of product , however increases at a decreasing rate .
Sometimes to choose a Design Quality level of b , which maximises the difference between Vlaue & Cost , while the
minimal customer expectation a is met.
C
For designed Quality o
S
level of C , the cost & t
value are equal . Cost
O
r
V
a Value
l
For any level above u
e
c( say d) the cost
exceeds the value .

Quality of Conformance
Quality of Conformance implies that a manufactured product or S must meet the standards selected in design phase .
In Mfg Sector – This phase – Degree to which Quality is controlled from procurement of RM to shipment of FG .
Consists of three broad areas :-
1) Defect Preventation
2) Defect finding (detection)
3) Defect analysis & rectification
For meeting this we have to work on
4) Design the tools , Equipments

5) Design of Process steps (PFD)
6) SOPs , OMS

Quality of Conformance
If such production system is not capable of

meeting the spec , the design phase is
effected . This feedback suggests that the
product be re-designed because the
current design cannot be produced using
the existing capability .
So there should be Constant

exchange of information between
design and manufacturing phases
so that a feasible design can be
achieved.
Quality of Performance
Quality of Performance is concerned with how
well the product functions .
It measures the degree to which the product or S

satisfies the customer .
If a service does not live up to customer

standards , then adjustment need to be made in
the design or conformance phase.

Quality Control & Quality Assurance
QC Definition :- A system that is used to maintain a desired level of quality in a product or service. This task is
achieved through –
a) Planning
b) Design
c) Use of Proper Equipment
d) Procedures
e) Inspection
f) Taking corrective actions
Quality is not just the responsibility of one person in the Organisation – this is the message.
Everyone involved directly or indirectly in the production of an item (or machine) is responsible.
QA Definition :- All those planned or systematic actions necessary to provide confidence that a product or service
will satisfy the given needs .
Definition as per ANSI/ASQC Standard A3 ,1987

Offline Quality Control
Offline Quality Control procedures deals with measures to select & choose controllable product &
process parameters in such a way that the deviation between the product or process output and the
standard will be minimised .
This is done through Product & process design .
The Goal is to come up with a design within constraints of resources and environment parameters such
that when production takes place , the output meets the standard.
The Product & process parameters are set before production begins .
Principle of experimental design & the Taguchi method …
Also the tools such as APQP , PPAP, Control Plan , PFD , FMEA,R&R

Some Questions Please / Answers in red
Qn :-
1) Inspecting a inside diameter by GO-NOGO plug gauge is a attribute inspection – True or False
2) Checking of thread by a pitch gauge is a attribute inspection – True or False
3) CEE inspection is a Inspection category of Aesthetic Quality or Perceived Quality
4) Specification 100 +5,+10mm , Observation 100 mm . Is it acceptable? - Unilateral tolerance
Lower limit = 100 +5 = 105 mm
Upper limit =100 +10 =110 mm
Specification = 105 mm to 110 mm
OK = 108 ,105
Rej = 100 , 102


Training On Baisics of Quality

Uploaded by

Copyright:

Available Formats

You might also like

Training On Baisics of Quality

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Training On Baisics of Quality

Uploaded by

Copyright:

Available Formats

Basics of Quality Assurance

Sibaram Das, 2/Jun/2021

Technology Innovation Leadership

3. Inspection – Attribute & Variable

4. Tolerance ,Limit , types of fits , examples

1) Ancient Egyptians – 5th Century B.C – Pyramids , Rome Built

2) Middle Age up-to 1800 s

3) Till 1983 – Phase -I

Technology Innovation Leadership

• Foreman Quality Control Period

A supervisor who directed the operation also responsible for

Technology Innovation Leadership

• Inspection Quality Control Period

• Standards (std.) were set.

Inspector checks Quality of the product after certain operation.

Technology Innovation Leadership

• Inspection Quality Control Period

Statistical Process Control (SPC) = process monitoring

Technology Innovation Leadership

Technology Innovation Leadership

Technology Innovation Leadership

Technology Innovation Leadership

Technology Innovation Leadership

AQL In Quality Control Sampling

AQL 1.0 c=0, which is a zero acceptance sampling plan

Technology Innovation Leadership

8) 1960 – Concept of Zero Defect

• Achieving Productivity through workers involvement

9) 1960 – Quality Circle – Gained in Japan

• Concept based on participation type management .

10) 1970 – 1983 – Total Quality Control – Organisation

• Participation of Operator to 1st line supervisor to

Technology Innovation Leadership

What is a “Cause and Effect Diagram”?

Technology Innovation Leadership

Technology Innovation Leadership

Cause and Effect Diagram Key Concepts

The interrelationships are generally qualitative and hypothetical.

Technology Innovation Leadership

Technology Innovation Leadership

Technology Innovation Leadership

Technology Innovation Leadership

Popularized by Armand V. Feigenbaum in a Harvard Business Review article[9] and book of the

Six Sigma applied with the principles of lean manufacturing and/or lean enterprise;

Technology Innovation Leadership

1960,Gradual 1990 Further

Sampling Plan Organisation wide

Technology Innovation Leadership

2.Features 4.Conformance 6.Serviciability 8.Percieved

1.Performance 3.Reliability 5.Durability 7.Aesthetics

Technology Innovation Leadership

Is defect & Non conformity are same ?

The Modern term of defect is Non Conformity

Technology Innovation Leadership

1. Structural – Length , Viscosity , Resistance.

2. Sensory – Feel ,appearance .

3. Time oriented – Warranty , Reliability