MOI UNIVERSITY

SCHOOL OF ENGINEERING DEPARTMENT OF

CHEMICAL & PROCESS ENGINEERING
CHP 522
ASSIGNMENT
CPE/1003/20-ALLAN KINOTI
CPE/0283/20-CELINE KICHWEN
CPE/1279/20-MORGAN MAGANGA
CPE/1820/20-FAITH NJERI
CPE/2080/20-CHEPTOO KAITTANY
i. Discuss quality control in industrial management

Quality control refers to the processes and methods used to ensure that products or
services conform to predefined quality standards. Its primary objectives include:
- Ensuring consistency in product quality.
- Identifying and correcting defects or deviations.
- Meeting regulatory and customer requirements.
- Reducing waste and rework.
- Enhancing customer satisfaction and brand reputation.

Quality Control Techniques and Tools

Industrial management employs various techniques and tools to implement quality
control effectively:

a. Statistical Process Control (SPC)

- Uses statistical methods to monitor and control production processes.
- Tools like control charts help identify variations and trends.

b. Inspection and Testing

- Involves examining raw materials, in-process products, and finished goods to ensure
compliance with standards.
- Techniques include visual inspection, dimensional measurement, and performance
testing.

c. Six Sigma
- A data-driven methodology aimed at reducing defects and improving processes.
- Uses the DMAIC (Define, Measure, Analyze, Improve, Control) framework.

d. Total Quality Management (TQM)

- A holistic approach that involves all employees in continuous quality improvement.
- Focuses on customer satisfaction, employee involvement, and process optimization.

e. Lean Manufacturing
- Aims to eliminate waste and improve efficiency while maintaining quality.
- Techniques include value stream mapping, 5S, and Kaizen.

f. Failure Mode and Effects Analysis (FMEA)

- Identifies potential failure points in a process and their impact on quality.
- Helps prioritize corrective actions.

g. Quality Function Deployment (QFD)

- Translates customer requirements into specific product or service features.
- Ensures that the final output aligns with customer expectations.
 ii. Describe the steps in quality control
Steps in the Quality Control Process
The quality control process typically involves the following steps:

a. Define Quality Standards

- Establish clear and measurable quality criteria based on customer requirements, industry
standards, and regulatory guidelines.

b. Plan Quality Control Activities

- Develop a quality control plan that outlines inspection points, testing methods, and
responsibilities.

c. Implement Quality Control Measures

- Execute the planned activities, such as inspections, testing, and process monitoring.

d. Monitor and Measure Performance

- Use tools like control charts, checklists, and audits to track quality performance.

e. Identify and Analyze Defects

- Investigate the root causes of defects using techniques like the 5 Whys or fishbone
diagrams.

f. Take Corrective Actions

- Address the root causes of defects and implement corrective measures.

g. Review and Improve

- Continuously evaluate the effectiveness of quality control processes and make
improvements as needed.

iii. Explain the fundamental basis of statistical quality control

Statistical Quality Control (SQC) is a methodology that uses statistical techniques to

monitor and control the quality of products and processes. It is a fundamental aspect of
quality management that helps organizations ensure consistency, reduce variability, and
improve overall quality. The basis of SQC lies in the application of statistical methods to
analyze data, identify trends, and make informed decisions about process adjustments.
Below is a detailed explanation of the fundamental basis of Statistical Quality Control:

1. Core Principles of Statistical Quality Control

SQC is grounded in several core principles:
- Variability Reduction: All processes exhibit some degree of variability. SQC aims to
identify and minimize this variability to ensure consistent quality.
- Data-Driven Decision Making: SQC relies on data collection and analysis to make
objective decisions about process performance.
- Process Control: By monitoring processes in real-time, SQC helps detect and correct
deviations before they result in defects.
- Continuous Improvement: SQC provides tools for ongoing evaluation and improvement
of processes.

2. Key Components of Statistical Quality Control

SQC consists of three main components:

a. Descriptive Statistics
- Descriptive statistics summarize and describe the characteristics of a dataset.
- Common measures include mean (average), median, mode, range, and standard
deviation.
- These statistics provide a snapshot of process performance and help identify trends or
patterns.

b. Statistical Process Control (SPC)

- SPC involves using control charts to monitor process performance over time.
- Control charts help distinguish between common cause variation (inherent to the
process) and special cause variation (due to external factors).
- By identifying special cause variation, organizations can take corrective actions to
maintain process stability.

c. Acceptance Sampling
- Acceptance sampling is used to determine whether a batch of products meets quality
standards.
- It involves inspecting a sample of items from a batch and using statistical methods to
infer the quality of the entire batch.
- This approach is particularly useful when 100% inspection is impractical or costly.

3. Tools and Techniques Used in SQC

SQC employs a variety of statistical tools and techniques to analyze and control quality:

a. Control Charts
- Control charts are graphical tools used to monitor process performance over time.
- They plot process data (e.g., measurements, defect counts) against control limits (upper
and lower bounds).
- Common types of control charts include:
- X-bar and R charts: Monitor the mean and range of a process.
- P charts: Track the proportion of defective items.
- C charts: Monitor the number of defects per unit.
 b. Histograms
- Histograms are bar charts that display the distribution of a dataset.
- They help visualize the frequency of different values and identify patterns such as
skewness or bimodality.

c. Pareto Analysis
- Pareto analysis is based on the Pareto principle (80/20 rule), which states that a small
number of causes often account for the majority of problems.
- Pareto charts prioritize issues by plotting the frequency or impact of different defects or
problems.

d. Scatter Diagrams
- Scatter diagrams plot pairs of variables to identify potential relationships or
correlations.
- They are useful for understanding how changes in one variable may affect another.

e. Cause-and-Effect Diagrams (Fishbone or Ishikawa Diagrams)

- These diagrams help identify potential causes of a problem by categorizing them into
major categories (e.g., materials, methods, machines, manpower).
- They are often used in conjunction with root cause analysis.

f. Process Capability Analysis

- Process capability analysis assesses whether a process can produce outputs within
specified tolerance limits.
- Key metrics include Cp (process capability index) and Cpk (process capability index
adjusted for centering).
4. Steps in Implementing Statistical Quality Control
The implementation of SQC typically involves the following steps:

a. Define Quality Characteristics

- Identify the key quality characteristics (e.g., dimensions, weight, strength) that need to
be monitored and controlled.

b. Collect Data
- Gather data on the selected quality characteristics through measurements, inspections,
or testing.

c. Analyze Data
- Use statistical tools (e.g., control charts, histograms) to analyze the data and identify
patterns or trends.
 d. Monitor Process Performance
- Continuously monitor the process using control charts to detect any deviations from the
desired performance.

e. Identify and Address Variations

- Investigate the causes of any special cause variations and take corrective actions to
eliminate them.

f. Improve Process Capability

- Use process capability analysis to identify opportunities for improving process
performance and reducing variability.
5. Benefits of Statistical Quality Control*
Implementing SQC offers several benefits:
- Improved Product Quality: Reduces variability and ensures consistent product quality.
- Cost Reduction: Minimizes waste, rework, and scrap by detecting and correcting defects
early.
- Enhanced Customer Satisfaction: Delivers products that meet or exceed customer
expectations.
- Data-Driven Decisions: Provides objective data for making informed decisions about
process improvements.
- Regulatory Compliance: Helps ensure compliance with industry standards and
regulations.

6. Challenges in Implementing SQC

Despite its benefits, SQC faces several challenges:
- Data Collection: Requires accurate and consistent data collection, which can be
resource-intensive.
- Complexity: Statistical methods can be complex and require specialized knowledge and
training.
- Resistance to Change: Employees may resist adopting new statistical tools and
techniques.
- Initial Investment: Implementing SQC may require significant upfront investment in
training, software, and equipment.

7. Applications of Statistical Quality Control

SQC is widely used across various industries, including:
- Manufacturing: Monitoring production processes to ensure product quality.
- Healthcare: Controlling the quality of medical devices and pharmaceuticals.
- Service Industry: Improving the consistency and reliability of service delivery.
- Supply Chain Management: Ensuring the quality of raw materials and finished goods.