United Machinists’ Post

Quality #Control #Plan in #Manufacturing/#Automotive #Industry ✨️ #Purpose: • To ensure that products meet or exceed customer requirements and industry standards. • To prevent defects and ensure product reliability, safety, and performance. 💡 #Key #Elements: 👉. #Quality #Objectives and #Standards: • Define specific quality objectives and standards for the product or process. • Establish acceptance criteria and tolerance limits. 👉. #Inspection and #Testing Procedures: • Determine the methods and frequency of inspections and tests to verify product quality. • Identify the equipment, tools, and gauges to be used. 👉. #Inspection and #Test #Points: • Establish specific points in the manufacturing process where inspections and tests will be performed. • Identify critical control points where defects are most likely to occur. 👉. #Inspection and #Test Records: • Document the results of inspections and tests, including any nonconformities found. • Maintain records for traceability and accountability. 👉 #Nonconformity Management: • Establish procedures for handling nonconforming products. • Determine the disposition of nonconforming products (e.g., rework, scrap). 👉. #Corrective and #Preventive Actions: • Identify and implement corrective actions to eliminate the root causes of nonconformities. • Develop preventive actions to prevent recurrence of defects. 👉. #Statistical #Process #Control (#SPC): • Use statistical methods to monitor and control manufacturing processes. • Identify trends and variations that may indicate potential quality issues. 💡 #Example in #Automotive Industry: #Quality Control Plan for #Vehicle Assembly: 👉. #Quality Objectives: • Achieve a zero-defect rate in vehicle assembly. • Ensure all vehicles meet or exceed safety and performance standards. 👉. #Inspection and #Testing Procedures: • Inspection of components before assembly. • Functional testing of assembled vehicles. • Road testing to verify performance and safety. 👉. #Inspection and #Test Points: • Component inspection at the receiving dock. • Sub-assembly inspection during assembly. • Final vehicle inspection before delivery. 👉. #Inspection and #Test Records: • Inspection reports detailing any nonconformities. • Test results for functional testing and road testing. 👉. #Nonconformity Management: • Nonconforming components are quarantined. • Nonconforming vehicles are held for repair or rework. 👉. #Corrective and #Preventive Actions: • Root cause analysis to identify the causes of nonconformities. • Implementation of corrective actions to eliminate defects. • Development of preventive actions to minimize the risk of future defects. 👉. #SPC: • Statistical monitoring of key assembly processes, such as torque values and dimensional accuracy. • Identification of trends and variations to ensure consistent quality. #quality #qualityassurance #qaqc #ContinuousImprovement #learningeveryday #helpinghands

Quality control (QC) in #manufacturing is a core concept that is the keystone for ensuring that products fulfill requirements and meet desired standards. These QC methods include a range of activities meant to regulate and improve production processes. In this article, we will provide a detailed overview of various quality control procedures, key components of quality control systems, and the main benefits of such systems. Moreover, QC implementation in #CNC #machine shops is also discussed. https://lnkd.in/gtzaAz6E

#Quality #Control #Plan in #Manufacturing/#Automotive #Industry ✨️ #Purpose: • To ensure that products meet or exceed customer requirements and industry standards. • To prevent defects and ensure product reliability, safety, and performance. 💡 #Key #Elements: 👉. #Quality #Objectives and #Standards: • Define specific quality objectives and standards for the product or process. • Establish acceptance criteria and tolerance limits. 👉. #Inspection and #Testing Procedures: • Determine the methods and frequency of inspections and tests to verify product quality. • Identify the equipment, tools, and gauges to be used. 👉. #Inspection and #Test #Points: • Establish specific points in the manufacturing process where inspections and tests will be performed. • Identify critical control points where defects are most likely to occur. 👉. #Inspection and #Test Records: • Document the results of inspections and tests, including any nonconformities found. • Maintain records for traceability and accountability. 👉 #Nonconformity Management: • Establish procedures for handling nonconforming products. • Determine the disposition of nonconforming products (e.g., rework, scrap). 👉. #Corrective and #Preventive Actions: • Identify and implement corrective actions to eliminate the root causes of nonconformities. • Develop preventive actions to prevent recurrence of defects. 👉. #Statistical #Process #Control (#SPC): • Use statistical methods to monitor and control manufacturing processes. • Identify trends and variations that may indicate potential quality issues. 💡 #Example in #Automotive Industry: #Quality Control Plan for #Vehicle Assembly: 👉. #Quality Objectives: • Achieve a zero-defect rate in vehicle assembly. • Ensure all vehicles meet or exceed safety and performance standards. 👉. #Inspection and #Testing Procedures: • Inspection of components before assembly. • Functional testing of assembled vehicles. • Road testing to verify performance and safety. 👉. #Inspection and #Test Points: • Component inspection at the receiving dock. • Sub-assembly inspection during assembly. • Final vehicle inspection before delivery. 👉. #Inspection and #Test Records: • Inspection reports detailing any nonconformities. • Test results for functional testing and road testing. 👉. #Nonconformity Management: • Nonconforming components are quarantined. • Nonconforming vehicles are held for repair or rework. 👉. #Corrective and #Preventive Actions: • Root cause analysis to identify the causes of nonconformities. • Implementation of corrective actions to eliminate defects. • Development of preventive actions to minimize the risk of future defects. 👉. #SPC: • Statistical monitoring of key assembly processes, such as torque values and dimensional accuracy. • Identification of trends and variations to ensure consistent quality. #quality #qualityassurance #qaqc #ContinuousImprovement #learningeveryday #helpinghands

#short_forms_used_in_industries. 5W+1H- what,why,when, where, who and How 4M- Man, machine, material and method 3R- Reduce, Re-use, Recycle 3M - Mura, Muri, Muda BIS- Bureau of Indian standard BOM- Bill of material CAPA- Corrective action preventive action CFT- Cross functional team CII- Confederation of Indian industry CLIT- clean lubricate inspection tighten CMM- co-ordinate measuring machine DFMEA- design failure mode effect and analysis DI- delivery instruction DOL- direct on line DWM- daily work management FIFO-first in first out FTR- first time right GMP-Good manufacturing practice IATF- International automotive task force ISO- International organisation for standard JD- Job description JIT- Just in time KPI- key performance indicator KRA- key result area LIFO- Last in first out MACE- Maruti centre for excellence MRN- Material receipt note MRR- Material receive receipt MSA- Measurement System analysis MTBF- Mean time between failures MSME- ministry of micro, small and medium enterprises NABL- National accreditation board for testing and calibration laboratory OEE- Overall equipment effectiveness OEM- Original equipment manufacturer OPL- One point lesson OTD- On time delivery PDIR-Pre delivery inspection report PFD- Process flow Diagram PFMEA- Process failure mode effect and analysis PO- Purchase order PPAP- Production part approval process PPC- Production planning and controlling PPE- Personal protective Equipment PR- Purchase requisition QA- Quality assurance QMS- Quality management system SGA- Small group activity RA- Roughness avg. RBA- Red bin Analysis ROI- Return on investment SHE- Safety health and Environment SMED- Single min. exchange of Die/tool SOP- Standard operating procedure SPC- Statistical process control SPM- Special purpose machine TPM- Total productive maintenance TQM- Total quality management TS- Technical specification UOM- unit of measurement VSM- Value stream mapping WI- Work instructions FQC- Final quality control IQC- Incoming quality control IPQC- In Process Quality control ERP- Enterprise resources planning ASQ- American society for quality OHSAS - Occupational health and safety assessment series HIRA- Hazard identification risk assessment CIQ- Critical to quality COPQ- Cost of poor quality PSW- Part submission warrant ECR- Engineering change request ECN- Engineering change note APQP- Advance product quality planning BOQ- Bill of quantities MRP- Material resources planning DOE- Design of experiment FMEA- Failure mode and effect analysis PDCA- Plan Do check act/action SDCA- Standardize Do check act/ action FPA- First part approval LPA- Last part approval

First Article on TQC by Armand V. Feigenbaum Control (design + material + product + process) ÷ Costs (inspection + rejects) X Customer satisfaction = TOTAL QUALITY CONTROL Sharing some lines from the same “Evidence points strongly to the fact that many businesses have quality-cost expenditures representing 7 % , 8 % , 10%, and even more of their cost of sales! Under these conditions, if quality must be not only maintained but upgraded, the wave of the future looks like an expensive one to ride. How many of the frailer business craft will be able to avoid getting swamped?” Fortunately, there is a way out of the di- lemma imposed on businessmen by increasingly demanding customers and by ever-spiraling costs of quality. This "way out"seems to lie in a new kind of quality control, which might be called "total quality control." The underlying principle of this total quality view - and its basic difference from all other concepts - is that, to provide genuine effective- ness, control must start with the design of the product and end only when the product has been placed in the hands of a customer who re- mains satisfied. The reason for this breadth of scope is that the quality of any product is affected at many stages of the industrial cycle: (1) Marketing evaluates the level of quality which customers want and for which they are will- ing to pay. (2) Engineering reduces this marketing evalu- ation to exact specifications. (3) Purchasing chooses, contracts with, and re- tains vendors for parts and materials. (4) Manufacturing engineering selects the jigs, tools, and processes for relay production. (5) Manufacturing supervision and shop oper- ators exert a major quality influence during parts making, subassembly, and final assembly. (6) Mechanical inspection and functional test check conformance to specifications. (7) Shipping influences the caliber of the pack- aging and transportation. In other words, the determination both of quality and of quality cost actually takes place throughout the entire industrial cycle. This is the reason why real quality control cannot be accomplished by concentrating on inspection alone, or design alone, or reject trouble-shooting alone, or operator education alone, or statistical analysis alone - important as each of these ni- dividual elements is. Such an amazing article published back in 1956 for that era, even make sense after decades. A must read for every professional. #TQC #TQM

In the dynamic world of manufacturing, precision is paramount. Understanding the nuanced difference between Quality Assurance (QA) and Quality Control (QC) is crucial, especially for companies operating in specialized sectors like injection molding. Quality Assurance is the proactive approach to ensure that processes are designed and executed to meet the desired outcome consistently. It's the framework that underpins the entire production cycle, ensuring that each step adheres to predefined standards. In the context of injection molding, QA involves validating the design and engineering processes, selecting optimal materials, and establishing protocols for seamless production runs. On the other hand, Quality Control is the reactive measure, focusing on inspecting the end product to identify defects and deviations from established standards. In injection molding, QC involves rigorous testing of the molded components, assessing dimensions, surface finish, and other critical parameters to ensure the final product meets the specified criteria. The symbiotic relationship between QA and QC is particularly crucial in the world of injection molding. The precision required in creating intricate molds demands a meticulous approach to both processes. QA sets the stage by optimizing the molding process, ensuring that each iteration adheres to design specifications. QC then steps in to scrutinize the finished product, identifying any anomalies and guaranteeing the end result aligns with the envisioned quality. In conclusion, the synergy between Quality Assurance and Control is the linchpin for success in the intricate realm of injection molding. Companies that grasp and leverage this dynamic interplay are better positioned to deliver products that not only meet but exceed the stringent expectations of their clients and industries. #ManufacturingExcellence #InjectionMolding #QualityAssurance #qualitycontrol

Quality control is essential for identifying and removing substandard products through inspections and tests. In manufacturing, the primary quality control methods are inspection and testing, supported by calibration to ensure precise results from test and measurement equipment. Explore further insights about quality control, improvement strategies, and its relationship with maintenance in this blog: https://bit.ly/3Tofw9t #QualityControl #QC #Manufacturing

TEC’s aerospace/defence courses are available in two formats and focus on essential quality tools, ensuring you meet and exceed industry standards – ✈Face-to-Face [web: https://lnkd.in/ebhJHgYP] 🛫e-Learning [web: https://lnkd.in/ewwNExsf] 💥invest in your future and the future of your organization’s quality management capabilities💥 🔆APQP & PPAP (AS9145)🔆 Learn to define roles, manage APQP and PPAP elements, and use tools like DFMEAs, PFMEAs, Control Plans, MSA, FAI, and SPC. 🔆Design FMEA🔆 Apply Risk-based thinking to product design, using tools like B-O-M, Block/Boundary Diagram, Interface Matrix, and more to create a value-adding DFMEA. 🔆Process FMEA & Control Plan🔆 Use Block/Boundary Diagrams, Interface Matrices and Process Flow Diagrams to apply risk-based thinking in production design, creating a value-adding PFMEA and an effective Control Plan. 🔆Measurement Systems Analysis (MSA)🔆 Understand gauge resolution and variation. Be able to select an appropriate gauge, conduct a Type 1 Gauge, Bias/Linearity and full GR&R studies on variable/attribute gauges. 🔆Process Control Methods & SPC🔆 Be able to use run charts, histograms and Anderson-Darling normality test to understand ‘voice-of-the-process’ and calculate process capability (Cpk). Deploy SPC in low volume, high mix environments. 🔆Human Factors (HF)🔆 Identify and address deeper root causes of human errors and use practical psychology and effective controls to motivate staff and prevent mistakes. 🔆Product & Safety Management System (SMS)🔆 Understand that product safety demands the deployment of a SMS. Be able to create the necessary organizational structures, accountabilities, policies, objectives and procedures. 🔆Foreign Object Damage (FOD)🔆 Understand the dangers/costs of FOD. Be able to implement practical implementation strategies to mitigate FOD risk using the cost-effective solutions. 🔆Prevention of Counterfeit Parts🔆 Understand that counterfeiting may have fatal consequences! Be able to design, document, deploy and audit necessary processes with awareness training for personnel for counterfeit parts prevention. 🔆First Article Inspection (FAI & AS9102)🔆 Understand the requirements for FAI contained in AS9102:2023 and the role of FAI in APQP & PPAP. Learn how to undertake and document FAI, complete the associated forms and avoid FAI report rejections. 🔆Disciplined Problem Solving and 8D🔆 Use the 8D approach to address problems with cross-functional team synergy, employing quality tools and techniques for effective solutions. 🌐Why Choose TEC?🌐 ✔Experienced trainers with extensive aerospace/defence backgrounds ✔Hands-on knowledge that you can apply immediately ✔Comprehensive coverage of all quality tools to meet industry demands #aerospace #defense #APQP #PPAP #DFMEA #PFMEA #MSA #SPC #FAI #wearenato #aerospacemanufacturing

Are you curious about First Article Inspection (FAI)? Do you know what it is and why it matters in manufacturing? Check out our latest article to learn everything you need to know about FAI, including its importance, how to prepare for it, and how to ensure quality control in your manufacturing process. #fai #firstarticleinspection #inspection #qualitycontrol #qcinspection