1. Quality control
(a) Briefly explain how the quality improvement helps to grow a production or service
organization.
What is quality?
Quality is about meeting the needs and expectations of customers
1. Increase customer loyalty with that product or service organization
Customers come again and repeat purchases again
Customers recommend the product or service to others.
Some customer after purchases if it has good quality he give good comments about it
with his friend. It is big help to growing to business.
2. Can build up good and strong brand reputation for quality
if Any company has good brand reputation they can easily can increase them sells.
Example: - Sony Company has god brand reputation for quality than other electric
equipment companies. Because they doing lot of quality improvements for them
product.
3. Retailers want to stock the product
Retailers are going to make stock mean production company can make big sales. It
helps growing them business. Because they can do lot of investment form them
money.
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2. Quality control
4. Any product or service has done quality improvements they perceived to be better
value for money.
It may commend a best price and will become price increase. But customers
purchase it because they think higher quality of that product.
Examples:-
We can buy Benz car more than 20 million But we can buy Toyota car 5 millions
.but some customs going to buy Benz car. Because they Benz product has better
value for money and that brand also has higher value for money
5. quality improvement help to make profitable business.
Product or service has good quality improvements mean they have good market sale
and market share and higher productivity/ efficiency and low production cost. That
mean after the quality improvement processes any company can earn lot of profit. as
6. higher the job security ,higher the job satisfaction
Now we know quality improvement help to make profitable business. The part of
profit goes All the employees of that company. Increase them bonus and they have
lot of benefits those things help increase to job satisfaction and job security.
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3. Quality control
(b) As a manufacture, how could you achieve a good quality product through its design and
production phases
What is quality of design?
Measure of how will be designed in product/ service to achieve the required
product
Product or service organization mainly follows two important quality concepts
Quality of designs
Quality of conformance to design
1. Quality of designs
Product or service organization measure how will be designed in product or service to
achieve the required product
How to achieve quality product though its design?
I. Normally designer collect data’s though the markets researches.
Researches gave data’s about obtain customers needs and what available now
in the market. Now designer can decide the best method. If any product
service can full fill customers requirements they can achieve higher sell and
can billed higher brand reputation.
II. Before decide final design designer have to consider man capacities of plant,
technologies are available.
III. Now designer decide actual specifications.
Following factors :-
1. Aesthetic characteristics
2. Performance characteristics
3. Obligatory regulations characteristics
4. environment factors important
2. Quality of conformance to design
Measures in what extent the product/service match with the design and customer
actually receives should confirm to the design.
Some time can depend on number of variables
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4. Quality control
02. (a) Explain why collective application of quality inspection, quality control and quality
assurance need to ensure a good quality product or service
Quality inspection
Inspection methods
1. Final inspection
2. Final and fixed intermediate Check 100%
3. Final and faxable intermittent
inspection
Check only
4. Patrol inspection samples
5. Centralized inspection
Advantages and purpose of Quality inspection:-
To detect poor quality products and separate them from acceptable quality products and
scrap, rework and sell them as second quality
In this Quality inspection process we can identified defect.
Don’t give any feed back to production process. After the inspected get a decision made
whether accept or reject
Disadvantages:-
1. Late detection of defects,
2. Higher cost of defective work
3. poor access to production supervision
4. scrap quantity higher
Due this disadvantages Quality inspection not enough to maintain higher quality
of the product.
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5. Quality control
Quality control
Main part of quality control:-
Is quality inspection where the product was checked to ensure that it meet the customer
requirements
Quality control a process for maintain standards and not for creating standards
Not like inspection gave the feed back to process to control / adjusts to minimize defects
in future production .this is main advantage of quality control.
Other advantages:-
to increase the profit of business
to enable to complete successfully
to enable to reduce cost of production
Disadvantages:-
Defect detect after the manufacturing
Higher manufacturing cost
Needing more man power to maintain quality
Quality assurance
Improving and stabilizing production and associated process to avoid or at least
minimize. Issues that led to the defects in the first place (before begin the production)
Related to systems and not to a product as in quality control
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6. Quality control
Quality assurance focus on
Quality manuals
Systems certification
Quality cost
Documentation
Now we can understand quality inspection or quality control or quality assurance not
enough to maintain to quality of product we want collective application of this three
concepts. This collective application has lot of advantages of inspection, quality control
and quality assurance
process chart of higher quality process
Before production Process of production Final products
Make quality manuals Maintain quality Final Inspection
standards Identify defects
Systems certification
In process Inspection
Give feed
back
Quality inspection Higher quality
products
Quality control
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7. Quality control
(b) What is ISO 9000 standard ? explain why ISO 9000 certification essential to obtain for
any production or service organization
The ISO 9000 family of standards represents an international consensus on good quality
management practices. It consists of standards and guidelines relating to quality
management systems and related supporting standard
ISO 9000 is a standard for a quality SYSTEMS not for product
Why ISO 9000 certification essential to obtain for any production or service
organization
1. increase customer satisfaction and retention
if any products has ISO 9000.that mean that products product by under the ISO
standards. Customers can purchases it without any afraid.
2. Create a more efficient, efficientive oparations
3. Enhance marketing
4. Improve employee motivation, awareness and morale
5. Promote internal trade
6. Increase profite
7. Reduce wastage and increase productivity
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8. Quality control
03.
(a) What do you understand by “quality cost” ?
Total costs incur to ensure that product/ service provides conformation to the customer
requirement.
Quality cost =Inspection cost +testing cost +quality standard maintain cost+ process
control cost+ defect rejection costs This all costs go to quality costs. but we can category this
cost under this factors
Quality cost categories
Cost of control (cost of cost of failure of
conformance) control
Prevention cost Apprasist cost Internal failure cost
External failure cost
Includes the cost of any Cost needed to Cost incur prior to the
action taken to investing Incur after transfer
discover the quality delivery to customer
quality defects of ownership to the
level during
1.Scrap customer
1. Process control production
2. Rework and repair
2. training quality 1.Replacement of
1.Inspection R.M 3.cost of wastage
personnel defect products
2. In process time
3. design review 2.complains
inspection
3. Quality audits
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9. Quality control
(b) A garment manufacturer has collected the following quality cost data. assign the to thefour
cost categories and present your finding as a percentage of total the cost
type of quality cost cost in rupees PC AC IF EF
scrap 75000 75000
rework and repair 80000 80000
final inspection 65000 65000
returned garments 55000 55000
in-process inspection 35000 35000
raw matrials inspection 25000 25000
retesting 30000 30000
quality planing 20000 20000
quality systems audite 20000 20000
quality improvement programme 55000 55000
quality training 15000 15000
total 475000 90000 145000 185000 55000
perecentage 18.9473684 30.5263158 38.9473684 11.578947
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10. Quality control
4. Quality control department following defect at various sections of a garment factory
1. In pattern making section : some pattern of size 12 ,14 and 18 mixed
Resent= Didn’t pest or didn’t named part name pattern sizes like that information
To avoid =Pest label to each parts include this details (part name ,pattern size )
2. In marker making : marker width is larger than average fabric roll width
Resent = didn’t measure fabric average width before make maker
To avoid = Must check the fabric width before make marker
3. Spreading section: larger cut garment panels than actual size
Resent = fabric spread in low tension
To avoid= Maintain proper and correct tension in spreading
4. Sewing section: skip stitches found with top stitching of shit pockets
Resent=due to hook irregular fails to pick up the loop tread
To avoid= use correct hook points without any damage ,
Feed machine in proper thread loop formation
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