-: Quality

Inspection :-

Prepared By: Mr. Prashant S. Kshirsagar (Sr.Manager-QA dept.)

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 -: Content :-
•Objective of Quality
•Process and Inspection
•Process Turtle diagram
•Process Control
•Inspection objective and
purpose
•Stages of inspection
•Methods of inspection
•Drawbacks of inspection
•Quality Cost
•Quality improvement ®
 -: Objective of Quality :-
(1) To decide about the standard of
Quality of a product that is easily
acceptable to the customer.
(2) To check the variation during
manufacturing.
(3) To prevent the poor quality
products reaching to the customer.

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 -: Process and Inspection :-
What is Process?
Ans: A series of actions or steps
taken in order to achieve a particular
product.

What is an inspection?
Ans: An inspection is the verification
of process/product quality to pre-
identified quality specifications
before, during or after the production
process.
Benefits of inspection: It helps to
control quality, reduces
manufacturing costs, eliminate scrap
losses and assignable causes of ®

defective work.
 -: Process Turtle Diagram :-
EQUIPMENT & FACILITIES: CONTROL PROCESSES:
PERSONNEL:
What equipment and resources are How is the process defined and who
Review employee skill lists for the is responsible? How are customer
required? process. Are there lists of skills for each
Is equipment suitable and properly requirements defined? What
position? Do they show enough detail? specifications apply defined?
maintained? This is often a finding, where lists are What objectives and targets apply
Is the work environment maintained? generic with inadequate detail. Training process? What controls/check points
Is there evidence of appropriate is a key process of any system. Are there are there?
maintenance of all equipment used by particular skills you want to evaluate? What acceptance criteria exist?
this process?
PROCESS OUPUTS:
PROCESS INPUTS: PROCESS What is the product produced by this
What triggers the process? NAME/DESCRIPTION: process? Are product measures in
What inputs are required? What steps are involved in the place to ensure that product meets
Where do the inputs come from? process? requirements? How are processes
Are they received in a timely What happens at each step in the
measured? Are product and process
manner? process?
What documents and records are measures achieved?
Are they fit for purpose? What feedback is received from
generated?
Is the process implemented in customers?
INSTRUCTIONS & accordance with procedures,
PROCEDURES: instructions or plans? KEY PERFORMANCE
Are controls applied as described? INDICATORS:
Review the documents that Review metrics and performance with
describe and control the process. Managers, Supervisors and operators.
Review all the important steps and SUPPORT PROCESSES: They should know how things are
activities of the process being As you audit, you will see how it running, objectives, customer issues,
audited. This info must be connects and interacts with other problem areas. If they do not, the
documented within the QMS. processes. Interactions with other requirements were not met. Is there ®

Evaluate how effectively the evidence that quality objectives and

processes are always important. Audit the
process flows through the steps. targets affected by this process are
relevant links to related processes and being achieved?
Do you see roadblocks or issues? support processes.
 Process Control
• Process Control: The process through which the standards are
established and met with standards is called Process Control.
The control process involves a
universal sequence of steps as
follows :
(1) Choose the control subject and
unit of measure.
(2) Set a standard value i.e., specify
the quality characteristics
(3) Choose a sensing device which
can measure.
(4) Measure actual performance.
(5) Interpret the difference between
actual and standard.
(6) Taking action, if any, on the ®

difference.
 Process Control
Factors Affecting Quality
(1) Men, Materials and Machines
(2) Manufacturing conditions
(3) Market research in demand of
purchases
(4) Money in capability to invest
(5) Management policy for quality
level
(6) Production methods and
product design
(7) Packing and transportation
(8) After sales service

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 -: Inspection objectives and Purpose :-
Objectives of Inspection
(1) To collect information regarding
the performance of the product
with established standards for the use
of engineering production,
purchasing and quality control etc.
(2) To sort out poor quality of
manufactured product and thus to
maintain standards.
(3) To establish and increase the
reputation by protecting customers
from receiving poor quality
products.
(4) Detect source of weakness and
failure in the finished products
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 -: Inspection objectives and Purpose :-
Purpose of Inspection
(1) To distinguish good products
from bad products
(2) To determine if the process is
changing.
(3) To determine if the process is
approaching the specification limits.
(4) To rate quality of product.
(5) To rate accuracy of inspectors.
(6) To measure the precision of
measuring instrument.
(7) To secure products – design
information.
(8) To measure process capability.
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 -: Stages of Inspection :-
(1) Inspection of incoming
materials: It is also called receiving
inspection. It consists of inspecting
and checking of all the purchased
raw materials and parts that are
supplied before they are taken on to
stock or used in actual
manufacturing. Inspection
may take place either at supplier’s
end or at manufacturer’s gate. If the
incoming materials are large in
quantity and involve huge
transportation cost it is economical
to inspect them at the place of
vendor or supplier. ®
 -: Stages of Inspection :-
(2) Inspection of production process:
The work of inspection is done while
the production process is
simultaneously going on. Inspection is
done at various work centers of men
and machines and at the critical
production points. This is having
advantage of preventing wastage of
time and money on defective units and
preventing delays in assembly.
(3) Inspection of finished goods: This
is the last stage when finished goods are
inspected and carried out before
marketing to see that poor quality
product may be either rejected or sold at ®

reduced price.
-: Methods of Inspection :-
1) 100% Inspection:
This type will involve careful inspection in
detail of quality at each strategic point or
stage of manufacture where the test involved
is non-destructive and every piece is
separately inspected. It requires more number
of inspectors and hence it is a costly method.
There is no sampling error. This is subjected
to inspection error arising out of fatigue,
negligence, difficulty of supervision etc.
Hence complete accuracy of influence is
seldomly attained.
It is suitable only when a small number of
pieces are there or a very high degree of
quality is required. Example : Jet engines, ®

Aircraft, Medical and Scientific equipment.

-: Methods of Inspection :-
2) Sampling Inspection:
In this method randomly selected samples
are inspected. Samples taken from different
batches of products are representatives. If
the sample prove defective, the entire
concerned is to be rejected or recovered.
Sampling inspection is cheaper and quicker.
It requires less number of Inspectors. Its
subjected to sampling errors but the magnitude of
sampling error can be estimated. In the case of
destructive test, random or sampling
inspection is desirable. This type of inspection
governs for automatic machines which are less
susceptible to chance variable and hence require
less inspection, suitable for inspection of products
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which have less precision importance and are less
costly.
 -: Drawbacks of Inspection :-
(1) Inspection adds to the cost of the product
but not for its value.
(2) It is partially subjective, often the inspector
has to judge whether a product passes or not.
Example : Inspector discovering a slight burnish
on a surface must decide whether it is bad or it
can fit.
(3) Fatigue and Monotony may affect any
inspection judgment.
(4) Inspection merely separates good and bad
items. It is no way to prevent the production
of bad items.

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 -: Quality Cost :-

(A) Failure costs :-

1) Internal failure costs:- They include,
a) Scrap : The net loss in labor and material resulting from
defectives which cannot economically be repaired or used.
b) Rework : Cost of defect correction to make them fit for use.
c) Retest : The cost of inspection and retest of products that
have undergone rework or other revision.
d) Down time : The cost of idle facilities resulting from defects.
(Example : Printing press down due to paper break).
e) Yield losses : The cost of process yield lower that might be
attainable by improved controls. Includes ‘‘overfill’’ of containers
(going to customers) due to variability in filling and measuring ®

equipment.
 -: Quality Cost :-
2) External failure costs:- They includes,
a) Complaint adjustment : All costs of
investigation and adjustment of justified
complaints attributable to defective product
or installation.
b) Returned material : All costs associated
with receipts and returned from the field.
c) Warranty charges : All costs involved in
service to customers under warranty
contracts.
d) Allowances : Costs of concessions made
to customers due to substandard products
being accepted by the customer as is include
loss in income due to down grading products
for sale as seconds.
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 -: Quality Cost :-
(B) Appraisal Costs: These costs include,
a) Incoming material inspection: The cost of
determining the quality of vendor/supplier made
products by inspection on receipt or at source.
b) Inspection and test: The cost of checking the
conformance of the product throughout its
progression, in the factory, including final acceptance
and check of packing. Also includes testing done at
customer’s premises prior to giving up the product to
the customer.
c) Maintaining accuracy of test equipment: Includes
the cost of operating the system that keeps the
measuring instruments and equipment in calibration.
d) Materials and services consumed: Includes costs
of product consumed through destructive tests,
materials consumed and services where significant.
e) Evaluation of stock: Include the costs of testing ®

products in field storage or in stock to evaluate

 -: Quality Cost :-
(C) Prevention Costs: It includes :
a) Quality Planning: This includes the broad array of
activities which collectively create quality plan, the
inspection plan, reliability plan, data system and
numeric specialized plans. It includes also preparation
of the manuals and procedures needed to communicate
these plans to all concerned.
b) New Product review: Includes preparation of bid
proposals evaluation of new design, preparation of test
and experiment programs and other quality activities
associated with the launching of new designs.
c) Training: The costs of preparing training programs
for attaining and improving quality performance
includes the cost of conducting formal training
programs as well.
d) Process control: Includes that part of process
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control which is conducted to achieve fitness for use as
distinguished from achieving productivity, safety etc.
-: Quality Improvement :-