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The document outlines key concepts in quality control and management, including Juran's Spiral of Quality, the four categories of quality costs, and the importance of quality audits. It also distinguishes between sporadic and chronic quality problems, describes the eight dimensions of quality, and explains control charts and their applications. Additionally, it details procedures for constructing p-charts and highlights the differences between p-charts and c-charts.

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arvidel2005
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2 views

Quality_Notes_Complete

The document outlines key concepts in quality control and management, including Juran's Spiral of Quality, the four categories of quality costs, and the importance of quality audits. It also distinguishes between sporadic and chronic quality problems, describes the eight dimensions of quality, and explains control charts and their applications. Additionally, it details procedures for constructing p-charts and highlights the differences between p-charts and c-charts.

Uploaded by

arvidel2005
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Quality Control and Management -

Complete Notes
1) Juran’s Spiral of Quality
Juran’s spiral of quality is a model that explains the continuous nature of quality
improvement. It emphasizes that each activity and process improvement leads to a new
level of performance and customer satisfaction. As organizations progress, they loop
through the cycle repeatedly, aiming for higher standards with each pass.
The spiral shows how quality planning, quality control, and quality improvement are
interconnected in a continuous process.

Sketch:

+-----------------------------+
| Customer Needs |
+-------------+--------------+
|
v
+-------------+--------------+
| Quality Planning |
+-------------+--------------+
|
v
+-------------+--------------+
| Operations/Production |
+-------------+--------------+
|
v
+-------------+--------------+
| Quality Control |
+-------------+--------------+
|
v
+-------------+--------------+
| Feedback & Improvement |
+-------------+--------------+
|
v
+-------------+--------------+
| New Customer Expectations |
+-----------------------------+

2) Four Categories of Quality Cost


1. 1. Prevention Costs: Costs related to activities that prevent defects (e.g., training, quality
improvement projects).
2. 2. Appraisal Costs: Costs of measuring and monitoring activities (e.g., inspection,
testing).
3. 3. Internal Failure Costs: Costs from defects found before delivery (e.g., rework, scrap).
4. 4. External Failure Costs: Costs after delivery (e.g., warranty claims, returns, reputation
damage).

3) Quality Audit Importance and Audit Program


A quality audit ensures compliance with quality systems and standards and helps identify
areas for improvement. It's crucial for ensuring continual quality improvement and
satisfying stakeholders.

Ingredients of an Audit Program:

 Audit scope
 Audit schedule
 Qualified auditors
 Audit checklist
 Reporting mechanism
 Follow-up actions

Importance of Audit Program:

A structured audit program helps in systematically evaluating processes, ensuring


consistency, and highlighting improvement opportunities. It also ensures accountability and
regulatory compliance.

4) Sporadic vs Chronic Quality Problems


Sporadic Problems: Sudden and unexpected, often due to assignable causes (e.g., tool
breakage).

Chronic Problems: Persist over time due to systemic issues (e.g., poor design).

Solution:
Sporadic – Address root cause immediately. Chronic – Use quality improvement tools like
Pareto Analysis, Root Cause Analysis.

5) Eight Dimensions of Quality (Automobile Example)


 Performance: Speed, mileage, acceleration.
 Features: GPS, infotainment, airbags.
 Reliability: Fewer breakdowns over time.
 Conformance: Meets regulatory standards.
 Durability: Long-lasting body, engine.
 Serviceability: Ease of repair and maintenance.
 Aesthetics: Design, color, interior appeal.
 Perceived Quality: Brand image and customer perception.

6) Conditions for Choosing the Appropriate Control Chart


+----------------------+
| Type of Data |
+----------------------+
|
+----------------+----------------+
| |
Variable Data Attribute Data
(Measured values) (Count values)
| |
+------+ +------------------+
| | | |
n≥2 n=1 Defective Items Defects per Item
| | | |
X̄ & R Chart I & MR Chart p-chart c-chart

7) Patterns in Control Charts


1. Random Pattern – Process is under control.
2. Run – Consecutive points on one side of mean.
3. Trend – Continuous increase or decrease.
4. Cycle – Periodic fluctuations.
5. Hugging CL – Over-controlled.
6. Hugging Limits – Risk of process going out of control.

8) Chance vs Assignable Causes


Chance Causes: Inherent, random variability (e.g., ambient temperature).
Assignable Causes: Identifiable, fixable causes (e.g., tool failure).
9) Control Charts for Attributes
p-Chart:
- Monitors proportion of defectives.
- Binomial data.

c-Chart:
- Monitors number of defects.
- Poisson data.

10) Procedure to Construct a p-Chart


1. Collect sample data.
2. Calculate proportion defective (p).
3. Find average (p̄ ).
4. Calculate control limits:
UCL = p̄ + 3√(p̄ (1-p̄ )/n)
LCL = p̄ - 3√(p̄ (1-p̄ )/n)
5. Plot chart.
6. Interpret.

11) Difference between p-Chart and c-Chart


p-Chart:
- Tracks proportion defective.
- Binomial data.
- Variable sample size.

c-Chart:
- Tracks defect count per unit.
- Poisson data.
- Constant sample size.

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