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CHAPTER 5
QUALITY CONTROL,
QUALITY ASSURANCE,
QUALITY IMPROVEMENT
Prepared by :
Afizal Azzizan
Masni-Azian Akiah
Siti Rodhiah Abdul Aziz
Umi Kalsom Kamarul Ariffin
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OVERVIEW
quality
:: depends on the stakeholder •MANAGEMENT
wants to see improved production numbers with acceptable
quality
• UNION
wants the best conditions and highest pay for employees
• EMPLOYEES
want consistent work in safe environment
• CUSTOMER
want value for their money
:: quality in manufacturing :
[ product should work as intended with minimum number of faults & failures ]
:: quality in service :
[ customer satisfaction in the primary measure ]
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OVERVIEW
QUALITY CONTROL QUALITY ASSURANCE QUALITY IMPROVEMENT
:: Planned inspection / :: Activity to ensure that :: Effort taken to increase
examination of a PROCESS implemented to efficiency of actions and
PRODUCT or SERVICES for produce the PRODUCT or procedures with the
a certain minimum levels SERVICE satisfy customer purpose of achieving
of quality. requirement in a additional benefits for the
systematic and reliable organization and its users.
fashion consistently.
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OVERVIEW
EXAMPLE : QC vs. QA vs. QI
ISO 9001
CERTIFIED
Engine
Casting
Painting
Trim Body
& Final Assembly
Kaizen / ICC /
Final
Inspection
Stamping 5S Program
INTERNAL
AUDITORS AUDIT
ORGANISATION
performance
QC
QA CUSTOMER
QI 4
QUALITY CONTROL
concept
• maintenance of standards of quality of manufactured goods
• process of making sure that products or services are made to
consistently high standards.
quality control can cover not just products, services, and processes, but also
people. Employees are an important part of any company. If a company has
employees that don’t have adequate skills or training, have trouble
understanding directions, or are misinformed, quality may be severely
diminished.
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QUALITY CONTROL
goal
implementation
INSPECTION MONITORING RECORD
Involves the examination of Routinely gather Anything (such as a
a product, service or information on all aspect document) providing
process for certain of the activity permanent evidence of
minimum levels of quality. information about past
Example : Statistical events.
Example : product Process Control (SPC)
specification, process Example : Employee
specification training record for year
2003 ~ 2009
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QUALITY CONTROL
implementation
• Traditional QC
PROBLEM
• not a value-added activity
• costly
• too late
• inspection done by the wrong
people.
• not compatible with more
modern production techniques.
• working capital is tied up in stocks
which cannot be sold
• disagreement at to what
constitutes as a “quality product”
inspection of products and services takes
place during and at the end of the
operations process
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QUALITY CONTROL
implementation
Example : Production
PRODUCTION
QUALITY ASSURANCE.
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QUALITY ASSURANCE
concept
• a set of activities designed to ensure the development and
maintenance process is adequate to ensure a system will meet
its objectives.
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QUALITY ASSURANCE
goal
• “HOW SURE ARE YOU??”
:: focus on the process involves, and make sure you do the right thing.
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QUALITY ASSURANCE
implementation
• Internal audit / First party audit
:: a systematic, independent and
documented process inspection conducted • NON-CONFORMANCE REPORT (NCR)
Issued to the audited area if non-
by members within the organization and compliance are found.
obtain evidence and evaluate it to The audited area should reply with the
determine where inspection criteria are correction and corrective action to close-
fulfilled. out the NCR.
• CERTIFICATION
• External audit / Second or Third party audit To show that the organization is complying
:: similar to internal audit, but conducted by to the quality standard.
Example : ISO 9001, ISO 14001
members not within the organization.
:: example - customers, independent
organizations / certification body.
‘Auditor’ should be able to tell if the deliverable seems acceptable based on the
process used to create it. That's why project auditors can perform a quality
assurance review on your project, even if they do not know the specifics of what
you are delivering. They don't know your project, but they know what good
processes look like. 12
QUALITY ASSURANCE
implementation
• The most popular tool used to determine quality assurance is the Shewhart Cycle
(developed by Dr. W. Edwards Deming), also known as PDCA.
A P
necessary for improvement and processes required to
if the results require deliver the desired results.
changes
C D
Check : Monitor and Do : Implement the process
evaluate the implemented developed.
process by testing the
results against the
predetermined objectives
• PDCA analyzes existing conditions and methods used to provide the product or
service to customer.
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QUALITY ASSURANCE
implementation development
production
design
installation documentation
service
• This introduced the rules: “fit for purpose" and "do it right the first time".
• It includes the regulation of the quality of raw materials, assemblies, products and
components; services related to production; and management, production, and
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inspection processes.
QUALITY ASSURANCE
QC. vs QA.
• Whereas quality control emphasizes testing and
blocking the release of defective products, quality
assurance is about improving and stabilizing
production and associated processes to avoid or at
least minimize issues that led to the defects in the
first place.
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QUALITY IMPROVEMENT
concept
• Keyword : IMPROVEMENT
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QUALITY IMPROVEMENT
goal
implementation
• 5 crucial activities to continual improvement :
1 maintain
communication
2 correct obvious
problems 3 look upstream
All improvement should be planned Study & research of the problems are
improvement. It is important to share required in order to identify the
Must look for the causes of problems
information before, during and after problems and to find solutions to
and not symptoms to problems.
attempting to make improvements. them.
4 document problems
and progress
5 monitor changes
A fundamental rule for any To ensure the right steps were taken
improvement program is to document to solve quality problems, or it may
the problems and progress. produce unintended consequences. 18
QUALITY IMPROVEMENT
implementation
:: example
KAIZEN •
•
A concept of continual improvement
implementation
:: example
KAIZEN
E L E M E N T S
customer focus
teamwork
just-in-time
quality circles
automation
labor/management cooperation
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QUALITY IMPROVEMENT
implementation
:: example
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QUALITY IMPROVEMENT
implementation
:: example
KAIZEN
5 STEP PLAN
(also known as 5S)
KAIZEN PRACTISE
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QUALITY IMPROVEMENT
KAIZEN PRACTISE
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QUALITY IMPROVEMENT
KAIZEN PRACTISE
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QUALITY IMPROVEMENT
KAIZEN PRACTISE
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QUALITY IMPROVEMENT
KAIZEN PRACTISE
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QUALITY IMPROVEMENT
implementation
An example : FADE MODEL example.
FOCUS: Define and verify the process to be
improved
implementation
An example : FADE MODEL example.
John is the owner of a motel.
• Using a FADE model John FOCUSED on the linens cycle of
housekeeping.
• He ANALYZED the way linens were handled and found that the
laundering process seemed to be inefficient.
• He DEVELOPED a step-by-step process for washing, drying, folding,
and storing the linens which he expected would speed up the process
and eliminate wasted effort.
• He then EXECUTED the process with his staff and will EVALUATE for
effectiveness on a weekly basis.
This is a cyclic process. Once you’ve made a change, you start all over again:
You evaluate the impact of your change
You focus down further
You analyze the problem to find the root cause(s)
Then develop methods for further improvement
And execute and evaluate again!
Repeat the process until the goal is achieved. 29
QUALITY IMPROVEMENT
implementation
Common problems during implementation of QI activity :
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QUALITY IMPROVEMENT
implementation
Management essential role in ensuring the success of QI:
• Encourage commitment
HOW?
..:: Establish company-wide council on quality improvement activity.
..:: Moral and physical support
summary
“Inspection with the aim of finding the
bad ones and throwing them out is too
late, ineffective, costly. Quality comes
not from inspection but from
improvement of the process."
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EMGT303 : QUALITY MANAGEMENT IN ORGANIZATION
summary
• QC, QA and QI is an important activity to ensure that the products /
services provided meets the customer expectations.
• Many tools available as a guidance to drive quality related activity.
• Quality should be viewed as a journey
• Therefore, success takes time.
• Progress of any quality activity shall be assessed / monitored and
being used as the input and basis for the next improvement activity.
• Internal best practice shall be shared as internal benchmarking.
• Poor labor management relations must be resolved
• Fear of change must be removed from the organization to ensure
success in the implementation of quality related activity.
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EMGT303 : QUALITY MANAGEMENT IN ORGANIZATION
references
Quality Management in Organization, InEd module
http://www.wisegeek.com/
http://en.wikipedia.org/wiki/Quality_control
http://en.wikipedia.org/wiki/Quality_assurance
http://en.wikipedia.org/wiki/Quality_management
http://www.unizg.hr/tempusprojects/glossary.htm
http://www.eskimo.com/~mighetto/lsbench.htm
http://membres.lycos.fr/hconline/kaizen_us.htm
http://chohmann.free.fr/
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