Arab Academy for Science, Technology & Maritime Transport

Assignment Chapter 10
Module Name: Operation Management

Student Full Name Mahmoud Shawky Ali

ID No. 20122071

Lecture Day Wend. 6-10 PM

Quality Control
Introduction
Quality control is defined as a process that evaluates output relative to a typical and takes corrective action
when output doesn’t meet standards. Quality control efforts that occur during production are mentioned as
statistical process control. The best companies design a top quality into the method , thereby greatly reducing the
necessity for inspection or control efforts.

INSPECTION
It is an appraisal activity which compares the final product to a standard. It is a vital but unappreciated
aspect of quality control. Inspection cannot be completely eliminated.

Inspection can occur at three stages: before production to make sure that inputs are acceptable,
during production to make sure that the conversion of inputs into outputs is proceeding in an
acceptable manner. and after production to make a final verification before passing goods to
customers.

How much To Inspect and how often :-

The amount of inspection can range from no inspection at all to inspection of each item and each
process depending on the cost and process delay as the inspection on the process increase lead to
cost increase and process delay but on the other hand the undetected defects decrease.

Where to inspect in the process:-

As the inspection adds to the cost of the product or service so we have to select the points where they
can do the most good and here are some important inspection points :-

1- Raw Materials : to make sure that it conforms to the quality standard

2- Finished product : to assure the customer satisfaction as the cost of inspection is much less than
repairing or replacing the product

3- Before costly operations : to save costs of labor and machine time

4- Before an irreversible process :- to save the cost of discard the nonconformance product as it
cannot be reworked.

Centralized VS On-site Inspection :-

In some situations inspection needs to be done on site and in another situations it needs to be done at
lab , the main reason in the decision is that if the advantages of specialized lab tests worth the time
and interruptions to obtain the results , on the other hand the onsite inspection include quicker
decisions .

Statistical Process Control

It used to evaluate the process output to decide if it in control or need corrective actions

Process Variability :-
All kind of process that generates output have some degree of variability and the issue is to decide if
this variations are within the acceptable range ( random ) or outside the acceptable range ( Non
random) and need corrective actions .

-Random Variations are natural, acceptable and the system described as in control.

- Nonrandom Variations have an assignable cause and can be eliminated and the system is described
as out of control
 Sampling and sample distribution :-
In statistical process control , periodic samples of the output are taken and it can be used to define
and judge the randomness of process variations , the variability of the sample statistics can be
described by the sampling distribution which is theoretical distribution that describe the random
variations

Central limit theorem states that, because the sample size increase the distribution of the sample
average approach Gaussian distribution

Sampling distributions and central limit theorem are used to distinguish between random and
randomness values of statistical sampling .

The control Process :-

Effective control process required the following steps :-

- Define , the first step is to define the important characteristics of the product , different
characteristics , may require different control purposes

- Measure , it is important to consider how measurement will be accomplished

- Compare , comparison between output and designed

- Evaluate , to distinguish between random and nonrandom variations which lead to judge the
process is it in control or out of control

- Correct , when the process is judged out of control , then corrective actions should be taken which
involves undercover the cause for nonrandom variations and correcting it

- Monitor Result , to assure the corrective action is effective and to make sure that the problem has
been eliminated

Control Charts : the voice of process

A control chart may be a time-ordered plot of sample statistics. we use It is used to distinguish
between random and nonrandom variability. It’s upper and lower limits called control limits; The
purpose of a control chart is to monitor the output to see if it is random.

A data point that falls outside of either limit would be taken as evidence that the tactic output could
even be nonrandom and , not “in control.” If that happens, the process would be halted to seek out
and proper the explanation for the nonrandom variation. The basis for the control chart is that the
sampling distribution, which essentially describes random variability.

Its important to recognize that , there is a small probability that a value falls outside the limits although
the process is random which referred to as the probability of type I error , where the error is
concluding nonrandomness is present when only randomness is present , and also we have the
meaning of type II error which describe the process is in control while it is really out of control.

Usually there are four commonly used control charts, two are used for variables and two are used for
attributes

1- Control Charts for variables :-

Mean and range charts are wont to monitor variables during which control charts for means monitor
the central tendency and therefore the range charts monitor the dispersion of the method

Mean Charts , sometimes called as X which based on the normal distribution and can be
constructed from on of the following two ways :-
 And if the standard deviation is unknown we can
use the range as a measure of process variability
which can be constructed from the following
formulas:-

Range Charts :- used to monitor the process dispersion which

very sensitive to any change in the dispersion , the control limit
for range charts constructed with these formulas :-

Using Mean and Range Charts :- as we shown , mean and range control charts provide different
prospective on a process as the mean is sensitive to the shift of the process mean and the range is
sensitive to the process dispersion so the both types can be used to monitor the process.

2- Control Charts for attributes :-

It used when the process characteristics is counted rather than measured , there are two types of
attribute control charts , one is the fraction of defective items in a sample ( ƿ-chart) , and one for the
number of defects per unit ( c-charts )

ƿ-chart : it used when the observations can be placed into one of two categories as good or bad ,
pass or fail , and when the data consists of multiple of samples on n observations .

the standard deviation of sampling distribution when ƿ is know is :-

 c-Charts :- used when the goal is to control the number of occurrences per unit , in which the
mean number of defect per unit is c and the standard deviation is √c
Managerial consideration concerning Control Charts :-
When we use the control charts we add to the cost and the time needed to the process , in the ideal
case we could achieve the quality required without the use of any control charts but in reality
managers should focused on where to use the control charts which is critical to the successful
operations and the sample size to achieve the optimum cost and time .

Run Test
Analysts always use supplement control chart with a run test to check the patterns in a sequence of
observations which help to do better job in detecting abnormalities in the process and provide some
insights to correct the process that is out of control .

Run is defined as sequence of observations with certain characteristics followed by one or more
observations that have different characteristics

Using control charts and run tests together

Usually both control charts and run tests are used to analyze the process output which involving the
following steps :-

- Compute the control limits for the process output

- Conduct the median and run tests

- Plot the points and decide if the output is random or not

What happens when a process exhibits possible nonrandom variation ?

Nonrandom variation is indicated when a point of observation is out side the control limits , here
managers should respond by investigating the cause as it may be false alarm ( Type I error ) or it may
be a real indication of an assignable cause for variation , if it is false alarm resume the process and
monitor for awhile to be sure and if an assignable cause it needed to be addressed and it can be
handled by the operator or by a team if it were complex .

Process Capability
Once the stability of the process has be accomplished , three commonly used terms referred to the
variability of the process

- Specifications established by the engineers and it indicates the range in which all output
observations must fall in to be acceptable

- Control Limits statistical limits in which the observations can be varies due to randomness

- Process Variability reflects the nature variability in the process

- Process Capability refers to the inherent variability of process output relative to the variation allowed
by the design specifications.

Capability analysis
It is determination of whether the variability inherent within the output of the method that's on top
of things falls within the suitable range of variability allowed by the planning specification for the
output . if it is not , managers must decide how to correct the situation .
To assess the capability of machine or a process , a Capability index can be computed from the
following formula

In the capable process , it must have capability index of at least 1 , however an index of 1 would
mean the process is barely capable

Improving process capability

It required changing the method target value and reducing the method variability that's inherent
within the process by simplifying , standardizing , upgrading equipment or automating .

Improving process capability lead to less need for inspection, lower warranty cost , higher
productivity and fewer complains about the service or product .

Limitation of Capability indexes

There are several risks associated with using capability index :-

- The process may not be stable , in which the index is meaningless

- The process is not centered and the index used gives misleading results .