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In Process Quality Control (IPQC) Planning

The document discusses In Process Quality Control (IPQC) planning, which involves identifying materials, equipment, processes and operators to enforce manufacturing rules and minimize errors. IPQC includes simple, rapid tests during production to check for good raw materials, proper process parameters, functional machines, and skilled operators. The objectives are to monitor quality, detect variations, and identify abnormalities immediately so corrective actions can be taken. The procedures involve operation testing according to specifications, training operators, decision making for rework or rejection, ensuring testing facilities are capable, using data displays, poka-yoke techniques, statistical quality control, and operator inspections to deliver products meeting specifications. The benefits are ensuring products meet requirements, accepting finished goods, reducing complaints and

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Muhammad Harriz Mohd Hasan
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121 views

In Process Quality Control (IPQC) Planning

The document discusses In Process Quality Control (IPQC) planning, which involves identifying materials, equipment, processes and operators to enforce manufacturing rules and minimize errors. IPQC includes simple, rapid tests during production to check for good raw materials, proper process parameters, functional machines, and skilled operators. The objectives are to monitor quality, detect variations, and identify abnormalities immediately so corrective actions can be taken. The procedures involve operation testing according to specifications, training operators, decision making for rework or rejection, ensuring testing facilities are capable, using data displays, poka-yoke techniques, statistical quality control, and operator inspections to deliver products meeting specifications. The benefits are ensuring products meet requirements, accepting finished goods, reducing complaints and

Uploaded by

Muhammad Harriz Mohd Hasan
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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In Process Quality Control (IPQC) Planning

A planned system, to identify the materials, equipment, processes and operators

● To enforce the flow of manufacturing and packaging operations according to the


established rules and practices (SOP).
● To minimize human error or to detect the error if and when it does occur.
● To pinpoint the responsibility to the personnel involved in each unit operation of
the entire process.

Generally a rapid and simple test procedures or inspections that are performed when
the manufacturing of the product batch is in process.

● Good raw materials


● Process parameters (SOP)
● Good machine
● Skilled operator

Objectives of IPQC

● To monitor all the features of a product that may affect its quality and to prevent
errors during processing. (BOM)
● To detect variations from the tolerance limits of the product so that prompt and
corrective actions can be taken. (Operation test)
● To detect any abnormality immediately and at the same time indicate the kind of
action needed. (Operation test/Metal line/Coil line)
Procedure for IPQC
● Operation test of a product must follow product specifications.
● On job training for operator to ensure operation test procedure are followed
○ Better and detailed work instruction (WI)
○ Understand which specification must be met of a product during testing
○ Troubleshooting
■ Example case, coil temperature does not met performance
specification
● Troubleshooting by charging more refrigerant
● Check whether performance met specification
● Root cause might be caused by refrigerant leaked during
connecting the pressure gauge
● Solution, increased the volume of refrigerant a little bit more
at refrigerant charging section
● Avoid unnecessary procedure during operation test
○ Decision-making whether to reject or rework
■ Wrong part specification installed
● Decision made to rework/replace the part
■ Wrong part dimension installed
● Decision made to rework/replace the part
■ Dented panel
● Decision made to rework/replace the part
■ Coil leakage
● Small leak (Rework)
● Big leak (Replace)
● Testing facilities
○ Testing facilities must be capable of simulating real operation of a product.
● Data display during operation test
○ Calibrated testing equipment to ensure true data displayed
○ Attention required to ensure product met specifications
● POKA-YOKE
○ Labeled parts
○ Coloring (Wire)
○ Sequence method (follow appropriate sequence of production procedures)
● Statistical Quality Control (SQC)
○ Critical parameter (ensure product performance during testing met
specifications)
● Inspection by production operator
○ Finished product must follow specification and be good in appearance (No
dented panel, scratched panel, loose bolt, refrigerant leaked)
Benefits of IPQC

● Ensure production of a product meets product specifications.


● ACCEPTED finished goods.
● Reduce chances of customer complaints.
● Links production operator with the customer expectation and specification.
● Ensure ‘First Time Right’ (FTR).
● Reduce chances of Rework and Rejection.

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