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QUALITY MANAGEMENT
CIPET BHOPAL
WHAT IS QUALITY
“THE ABILITY OF YOUR PRODUCT OR SERVICE
TO SATISFY YOUR CUSTOMERS.”
SEVEN QC TOOLS
THE SEVEN BASIC TOOLS OF QUALITY IS A
DESIGNATION GIVEN TO A FIXED SET OF
GRAPHICAL TECHNIQUES IDENTIFIED AS BEING
MOST HELPFUL IN TROUBLESHOOTING ISSUES
RELATED TO QUALITY. THIS TECHNIQUE IS USED
TO SOLVE THE VAST MAJORITY OF QUALITY-
RELATED ISSUES.
WHAT ARE SEVEN QC TOOLS
THEY ARE THE FOLLOWING SEVEN TOOLS.
1.PARETO CHART
2.CAUSE AND EFFECT DIAGRAM
3.CHECK SHEET
4.FLOW CHART
5.HISTOGRAM
6.SCATTER DIAGRAM
7.CONTROL CHART
PARETO CHART
IN PARETO CHART, THE VERTICAL AXIS REPRESENTS
PROPORTION, AND THE HORIZONTAL AXIS
REPRESENTS ITEMS.BAR GRAPS REPRESENTING THE
ITEMS ARE SORTED FROM THE LEFT IN
DESCENDING ORDER IN TERMS OF THE VALUES. IN
ADDITION, THE CUMULATIVE FREQUENCY
DISTRIBUTION CURVE, A LINE CONNECTING THE
CUMULATIVE PERCENTAGES UP TO EACH ITEMS) IS
ALSO DRAWN. THE PURPOSE OF THE PARETO
CHART IS TO HIGHLIGHT THE MOST IMPORTANT
AMONG A (TYPICALLY LARGE) SET OF FACTORS.
IN QUALITY CONTROL,
CAUSE AND EFFECT DIAGRAM
COMMON USES OF CAUSE AND EFFECT
DIAGRAM ARE PRODUCT DESIGN AND QUALITY
DEFECT PREVENTION. THE OTHER NAME IS
FISHBONE DIAGRAM.
• PEOPLE: ANYONE INVOLVED WITH THE PROCESS
• METHODS: HOW THE PROCESS IS PERFORMED AND THE
SPECIFIC REQUIREMENTS FOR DOING IT, SUCH AS POLICIES,
PROCEDURES, RULES, REGULATIONS AND LAWS
• MACHINES: ANY EQUIPMENT, COMPUTERS, TOOLS, ETC.
REQUIRED TO ACCOMPLISH THE JOB
• MATERIALS: RAW MATERIALS, PARTS, PENS, PAPER, ETC. USED
TO PRODUCE THE FINAL PRODUCT
• MEASUREMENTS: DATA GENERATED FROM THE PROCESS
THAT ARE USED TO EVALUATE ITS QUALITY
• ENVIRONMENT: THE CONDITIONS, SUCH AS LOCATION, TIME,
TEMPERATURE, AND CULTURE IN WHICH THE PROCESS
OPERATES
CAUSES ARE USUALLY GROUPED INTO MAJOR
CATEGORIES TO IDENTIFY THESE SOURCES OF
VARIATION. THE CATEGORIES TYPICALLY INCLUDE:
CAUSE AND EFFECT DIAGRAM
FLOW CHART
A FLOWCHART IS A TYPE OF DIAGRAM THAT
REPRESENTS AN ALGORITHM, WORKFLOW OR
PROCESS, SHOWING THE STEPS AS BOXES OF
VARIOUS KINDS, AND THEIR ORDER BY
CONNECTING THEM WITH
ARROWS. FLOWCHARTS ARE USED IN
ANALYZING, DESIGNING, DOCUMENTING OR
MANAGING A PROCESS OR PROGRAM IN
VARIOUS FIELDS
FLOW CHART
CHECK SHEET
• CHECK SHEET IS A TABLE THAT LISTS CHECK
ITEMS TO FACILITATE INSPECTIONS.
CHECK SHEET
CHECK SHEETS TYPICALLY EMPLOY A HEADING THAT
ANSWERS THE FIVE WS:
• WHO FILLED OUT THE CHECK SHEET
• WHAT WAS COLLECTED (WHAT EACH CHECK
REPRESENTS, AN IDENTIFYING BATCH OR LOT
NUMBER)
• WHERE THE COLLECTION TOOK PLACE (FACILITY,
ROOM, APPARATUS)
• WHEN THE COLLECTION TOOK PLACE (HOUR, SHIFT,
DAY OF THE WEEK)
• WHY THE DATA WERE COLLECTED
CHECK SHEET
HISTROGRAM
HISTROGRAM REPRESENTS THE DISTRIBUTION
OF DATA BY USING BAR GRAPH. THE VERTICAL
AXIS REPRESENTS THE FREQUENCY , AND THE
HORIZONTAL AXIS REPRESENTS BINS OF DATA. IT
IS ALSO CALLED A FREQUENCY DISTRIBUTION
CHART. A HISTOGRAM IS A GRAPHICAL
REPRESENTATION OF THE DISTRIBUTION OF
DATA.
HISTROGRAM
SCATTER DIAGRAM
SCATTER DIAGRAM IS A DIAGRAM IN WHICH
DATA OF TWO ITEMS ARE PLOTTED.
CONTROL CHARTS
CONTROL CHARTS SHOWN THE TREND OF AN
ITEM AND INDICATES WHETHER THE ITEM IS
UNDER CONTROL OR NOT. WE CAN CONCLUDE
THAT THE ITEM IS UNDER CONTROL AS LONG AS
THE VALUES STAY BETWEEN THE UPPER
CONTROL LIMIT(UCL) AND LOWER CONTROL
LIMIT(LCL), ALLOWING THE VARIANCE TO A
CERTAIN EXTENT.
CONTROL CHART
QUALITY CIRCLE
A QUALITY CIRCLE IS A GROUP
OF WORKERS WHO DO THE SAME OR SIMILAR
WORK(USUALLY 3 TO 12 EMPLOYEES) WHO
MEET REGULARLY TO IDENTIFY, ANALYZE AND
SOLVE WORK-RELATED PROBLEMS.
THESE MAY CONCERN QUALITY,
PRODUCTIVITY, SAFETY, JOB STRUCTURE,
PROCESS FLOW, CONTROL MECHANISM,
AESTHETICS OF THE WORK AREA .
QUALITY CIRCLE
QUALITY CIRCLE IS A PARTICIPATIVE
MANAGEMENT SYSTEM IN WHICH WORKERS
MAKE SUGGESTIONS AND IMPROVEMENTS FOR
THE BETTERMENT OF ORGANIZATIONS.
QUALITY CIRCLE
CONCEPT OF QUALITY CIRCLE
THE QC CONCEPT HAS THREE MAJOR ATTRIBUTES
THESE ARE:
1- QC IS A FORM OF PARTICIPATIVE MANAGEMENT.
2- QC IS A HUMAN RESOURCE DEVELOPMENT
TECHNIQUE.
3- QC IS A PROBLEM SOLVING TECHNIQUE.
CHARACTERISTICS OF QC
THE CHARACTERISTICS OF QC AS MANAGEMENT
TOOL FOR IMPROVING PRODUCTIVITY AND
QUALITY MAY BE LISTED AS BELOW:
1- QC ARE SMALL PRIMARY GROUPS OF
EMPLOYEES/WORKERS WHOSE LOWER LIMIT IS
3 AND UPPER LIMIT IS 12.
QUALITY CIRCLE
2- THE MEMBERSHIPS OF QC ARE MOST
VOLUNTORY. THE WORKERS/EMPLOYEES
INTERESTED IN SOME AREA OF WORK
IMPROVEMENT MAY COME TOGETHER TO FORM A
CIRCLE.
3- EACH CIRCLE IS LED BY THE AREA SUPERVISOR.
ALSO THEY ARE NORMALLY CO-ORDINATED
CENTRALLY IN ORGANIZATION BY A PERSON WHO
HAS BEEN TRAINED AS A FACILITATOR.
QUALITY CIRCLE
4-THE MEMBERS MEET REGULARLY EVERY WEEK OR
ACCORDING TO AN AGREED SCHEDULE.
5- THE CIRCLE MEMBERS ARE SPECIALLY TRAINED
IN TECHNIQUES OF ANALYSIS AND PROBLEM
SOLVING IN ORDER TO PLAY THEIR ROLE
EFFECTIVELY.
6- THE BASIC ROLE OF CIRCLE IS TO IDENTIFY AND
SOLVE WORK RELATED PROBLEMS FOR IMPROVING
QUALITY AND PRODUCTIVITY.
ADVANTAGE OF QC
1-PROMOTE HIGH LEVEL OF PRODUCTIVITY AND
QUALITY MINDEDNESS.
2-SELF AND MUTUAL DEVELOPMENT OF
EMPLOYEES.
3-CREATING TEAM SPIRIT AND UNITY OF
ACTION.
4-INCREASED MOTIVATION, JOB SATISFACTION
AND PRIDE IN THEIR WORK.
ADVANTAGE OF QC
5- REDUCED ABSENTEESISM AND LABOUR
TURNOVER.
6-WASTE REDUCTION.
7-COST REDUCTION.
8-IMPROVED COMMUNICATION.
9-SAFETY IMPROVEMENT.
10-TRAINED STAFF.
11-LEADERSHIP DEVELOPMENT.
12-IDENTIFY WORK RELATED PROBLEM AND SOLVES
THEM EFFECTIVELY
QUALITY MANAGEMENT
QM ENSURES THAT AN ORGANIZATION
PRODUCT OR SERVICE IS CONSISTANT. IT HAS
FOUR MAIN COMPONENTS:-
1-QUALITY PLANNING
2- QUALITY CONTROL
3- QUALITY ASSURANCE
4- QUALITY IMPROVEMENT
QUALITY MANAGEMENT
QUALITY MANAGEMENT IS FOCUSED NOT ONLY
ON PRODUCT AND SERVICE QUALITY BUT ALSO
ON TO MEANS TO ACHIEVE IT. QUALITY
MANAGEMENT, THEREFORE USES QUALITY
ASSURANCE AND CONTROL OF PROCESSES AS
WELL AS PRODUCTS TO ACHIEVE MORE
CONSISTENT QUALITY.
QUALITY MANAGEMENT
PDCA
PDCA (PLAN–DO–CHECK–ACT OR PLAN–DO–
CHECK–ADJUST) IS AN ITERATIVE FOUR-STEP
PROBLEM SOLVING TYPICALLY USED IN QUALITY
CONTROL. IT IS ALSO KNOWN AS DEMING CYCLE.
IT IS FOUR-STEP
MANAGEMENT METHOD USED IN BUSINESS FOR
THE CONTROL AND CONTINUOUS IMPROVEMENT
OF PROCESSES AND PRODUCTS. IT IS ALSO KNOWN
AS THE DEMING CIRCLE.
PDCA CYCLE
PLAN DO
ACT
CHECK
THE FOUR PHASES IN THE PLAN-DO-
CHECK-ACT CYCLE INVOLVE:
PLAN: SET GOALS BASED ON CUSTOMER NEEDS.
DO: IMPLEMENT THE PLAN AND MEASURE ITS
PERFORMANCE.
CHECK: ANALYZE WHAT HAPPENED
ACT: MAKE SURE IMPROVEMENT IS PERMANENT
BENEFITS OF THE PDCA CYCLE
1-PROBLEM SOLVING PROCESS
2-CONTINUOUS IMPROVEMENT
3-HUMAN RESOURCES DEVELOPMENT
4-NEW PRODUCT DEVELOPMENT
5-PROCESS TRAILS
6-PROJECT MANAGEMENT
7-DAILY ROUTINE MANAGEMENT FOR THE
INDIVIDUAL AND OR THE TEAM
COST OF QUALITY
THE COSTS OF CARRYING OUT THE COMPANY
QUALITY FUNCTIONS(MEETING THE QUALITY
NEEDS OF THE CUSTOMERS) ARE KNOWN AS
COSTS OF QUALITY. THESE INCLUDES:
1- MARKET RESEARCH COSTS OF DISCOVERING
THE QUALITY NEEDS OF THE CUSTOMERS.
2-THE PRODUCT RESEARCH AND DEVELOPING
COST.
COST OF QUALITY
3-THE DESIGN AND MANUFACTURING COST.
4-COST OF INSPECTION AND TEST.
5-COST OF DEFECT PREVENSION.
6-COST OF SCRAP, QUALITY FAILURE.
7-COST OF QUALITY ASSURANCE.
THE QUALITY COSTS BE DEFINED IN
FOUR CATEGORIES:
1- COST OF PREVENTION
2- COST OF APPRAISAL
3-COST OF INTERNAL FAILURES
4-COST OF EXTERNAL FAILURES
COST OF QUALITY
COST OF QUALITY
COST OF PREVENTION
1- COST OF QUALITY PLANNING
2- COST OF DOCUMENTING
3- PROCESS CONTROL COST
4- QUALITY EDUCATION AND TRANNING
5- QUALITY IMPROVEMENT PROJECTS
COST OF APPRAISAL
• TEST AND INSPECTION OF PURCHASED
MATERIALS
• ACCEPTANCE TESTING
• CHECKING LABOR
• SETUP FOR TEST OR INSPECTION
• TEST AND INSPECTION EQUIPMENT
• QUALITY AUDITS
COST OF INTERNAL FAILURE
• SCRAP
• REWORK
COST OF EXTERNAL FAILURE
• COMPLAINTS IN WARRANTY
• COMPLAINTS OUT OF WARRANTY
• PRODUCT SERVICE
• PRODUCT LIABILITY
• PRODUCT RECALL
• LOSS OF REPUTATION
QUALITY ASSURANCE
QUALITY ASSURANCE (QA) IS A WAY OF
PREVENTING MISTAKES OR DEFECTS IN
MANUFACTURED PRODUCTS AND AVOIDING
PROBLEMS WHEN DELIVERING SOLUTIONS OR
SERVICES TO CUSTOMERS. WHICH ISO
9000 DEFINES AS "PART OF QUALITY
MANAGEMENT FOCUSED ON PROVIDING
CONFIDENCE THAT QUALITY REQUIREMENTS
WILL BE FULFILLED
QUALITY ASSURANCE
QUALITY ASSURANCE MEANS ENSURING
CONFIRMETTING OF THE QUALITY TO THE
REQUIRED BASIC SPECIFICATION OR GIVEN
NEEDS.
THE STAGE IN CONSIDERATION OF TOTAL
QUALITY OF PRODUCT RELATED TO QUALITY
ASSURANCE-
QUALITY ASSURANCE
1- DESIGN STAGE
2-MANUFACTURING STAGE
3-FIELD OBSERVATION
QUALITY ASSURANCE
1-DESIGN STAGE-TO ENSURE THAT THE QUALITY
OF DESIGN IS ACCORDING TO THE NEEDS OF
THE CUSTOMERS.
2-MANUFACTURING STAGE-TO CHECK
WHETHER THE QUALITY OF PRODUCTS
MANUFACTURED CONFORMS TO THE DESIGN
SPECIFICATIONS.
QUALITY ASSURANCE
3-FIELD OBSERVATION- RELIABILITY AND
PERFORMANCE ANALYSIS.
FUNCTION OF QUALITY ASSURANCE
1- PROCESSING OF FIELD COMPLAINTS.
2- QUALITY RATING OF OUT GOING PRODUCTS.
3- QUALITY SURVEY OR AUDIT.
4-PREPARATION OF EXECUTIVE REPORT ON
QUALITY.
5- SETTING UP QUALITY LEVEL INSPECTION
PLANNING.
6- DISPOSITION OF NON- CONFIRMING PRODUCT.
ADVANTAGE OF QUALITY
ASSURANCE
1- FEWER DEFECTS
2- LESS SCRAP
3- BETTER QUALITY
4-GOOD CUSTOMER RELATION.
5- HIGHER PRODUCTIVITY.
6-LESS INSPECTION REFLECT.
6 SIGMA
SIX SIGMA IS A SET OF TECHNIQUES AND TOOLS
FOR PROCESS IMPROVEMENT. IT WAS DEVELOPED
BY MOTOROLA IN 1986.
SIX SIGMA SEEKS TO IMPROVE THE QUALITY OF
PROCESS OUTPUTS BY IDENTIFYING AND
REMOVING THE CAUSES OF DEFECTS (ERRORS) AND
MINIMIZING VARIABILITY IN MANUFACTURING AND
BUSINESS PROCESSES. IT USES A SET OF QUALITY
MANAGEMENT METHODS.
6 SIGMA
EACH SIX SIGMA PROJECT CARRIED OUT WITHIN
AN ORGANIZATION FOLLOWS A DEFINED
SEQUENCE OF STEPS AND HAS QUANTIFIED
VALUE TARGETS, FOR EXAMPLE REDUCE
PROCESS CYCLETIME, REDUCE POLLUTION,
REDUCE COSTS, INCREASE CUSTOMER
SATISFACTION AND INCREASE PROFIT.
6 SIGMA
THERE ARE TWO SIX SIGMA PROCESSES-
1-DMAIC PROCESS
2-DMADV PROCESS
DMAIC PROCESS
DMAIC IS USED FOR PROJECTS AIMED AT
IMPROVING AN EXISTING BUSINESS PROCESSES.
DMAIC PROCESS
DMAIC PROCESS
THE DMAIC PROJECT METHODOLOGY HAS FIVE
PHASES:
1-DEFINE- * DEFINE THE PROJECT PURPOSE AND
SCOPE.
*IDENTIFY HIGH LEVEL PROCESSES FOR
IMPROVEMENT.
* DETERMINE CUSTOMER NEEDS AND BENEFITS.
DMAIC PROCESS
2-MEASURE-
*IDENTIFY THE GAP BETWEEN CURRENT AND
REQUIRED PERFORMANCE.
*IDENTIFY POTENTIAL AREAS FOR
IMPROVEMENTS.
*PINPOINT PROBLEMS LOCATIONS AND
OCCURRENCES.
DMAIC PROCESS
3-ANALYZE-
• IDENTIFY ROOT CAUSES AND VALIDATE ROOT
CAUSES AGAINST CAPTURED DATA.
• DETERMINE IMPROVEMENTS THAT NEEDS TO
BE MADE.
DMAIC PROCESS
4-IMPROVE- IMPROVE OR OPTIMIZE THE
CURRENT PROCESS BASED UPON DATA ANALYSIS
USING TECHNIQUES SUCH AS DESIGN OF
EXPERIMENTS, POKA YOKE OR MISTAKE
PROOFING.
DMAIC PROCESS
5-CONTROL-
• PERFORM BEFORE AND AFTER ANALYSIS.
• DOCUMENTS RESULTS AND DETERMINE NEXT
STEP RECOMMENDATIONS.
DMADV PROCESS
DMADV IS USED FOR NEW PROJECTS OR NEW
BUSINESS PROCESS.
DMADV PROCESS
DMADV PROCESS
THE DMAIC PROJECT METHODOLOGY HAS FIVE
PHASES:
1-DEFINE- DEFINE THE PROJECT GOAL AND
CUSTOMER( INTERNAL AND EXTERNAL
DELIVERABLES.
2-MEASURE- MEASURE AND DETERMINE
CUSTOMER NEEDS AND SPECIFICATIONS.
DMADV PROCESS
3-ANALYZE- ANALYZE THE PROCESS OPTIONS TO
MEET THE CUSTOMER NEEDS.
4-DESIGN- DESIGN THE PROCESS TO MEET THE
CUSTOMER NEEDS.
5-VERIFY- VERIFY THE DESIGN PERFORMANCE
AND ABILITY TO MEET CUSTOMER NEEDS.
JIT(JUST-IN-TIME)
J-I-T IS AN APPROACH THAT SEEKS TO
ELIMINATES ALL SOURCES OF WASTE IN
PRODUCTION ACTIVITIES BY PROVIDING THE
RIGHT PART AT RIGHT PLACE AT THE RIGHT TIME
BENEFITS OF JIT
1-REDUCTION IN INVENTORY
2-IMPROVED QUALITY
3-REDUCED SPACE REQUIREMENTS
4-SHORTER LEAD TIMES
5-LOWER PRODUCTION COSTS
6-INCREASED PRODUCTIVITY
7-INCREASED MACHINE UTILIZATION
8-GREATER FLEXIBILITY
POKA-YOKE
‘POKA’ : MISTAKE ‘YOKE’ : PROOFING
• A POKA-YOKE IS ANY MECHANISM IN A LEAN
MANUFACTURING PROCESS THAT HEALPS AN
EQUIPMENT, OPERATOR AVOID(YOKE)
MISTAKES(POKA).
• ITS PURPOSE IS TO ELIMINATE PRODUCT
DEFECTS BY PREVENTING, CORRECTING AND
DRAWING ATTENTION TO HUMAN ERRORS AS
THEY OCCUR.
POKA-YOKE
• THE CONCEPT WAS FORMALIZED AND THE
TERM ADOPTED BY SHIGEO
SHINGO(JAPANESE INDUSTRIAL ENGINEER) AS
PART OF THE TOYOTA PRODUCTION SYSTEM.
POKA-YOKE
• THIS TOOL CAN BE APPLIED TO ANY PROCESS,
BE IT IN MANUFACTURING OR THE SERVICE
INDUSTRY.
POKA-YOKE
BENEFITS OF POKA-YOKE
• ELIMINATION OF SET-UP ERRORS AND IMPROVED
QUALITY
• DECREASED SET-UP TIMES WITH ASSOCIATED
REDUCTION IN PRODUCTION TIME AND IMPROVED
PRODUCTION CAPACITY
• SIMPLIFIED AND IMPROVED HOUSEKEEPING
• INCREASED SAFETY
• LOWER COSTS
• LOWER SKILL REQUIREMENTS
• INCREASED PRODUCTION FLEXIBILITY
• IMPROVED OPERATOR ATTITUDES.
THE 5S SYSTEM
5S IS A BASIC, FUNDAMENTAL, SYSTEMATIC
APPROACH FOR PRODUCTIVITY, QUALITY AND
SAFETY IMPROVEMENT IN ALL TYPES OF BUSINESS.
THE 5S ARE:-
1-SORT
2-SET IN ORDER
3-SHINE
4-STANDARIZE
5-SUSTAIN
THE 5S SYSTEM
1-SORT- ELIMINATE UNNECESSARY ITEMS FROM THE
WORKPLACE.
2-SET IN ORDER- ARRANGE ITEMS SO THAT THEY ARE EASY TO
USE, FIND AND PUT AWAY.
3-SHINE- KEEP THE ITEMS AND WORK AREA NEAT AND CLEAN.
4-STANDARDIZE- CREATE A CONSISTENT APPROACH TO TASKS
AND PROCEDURES.
5-SUSTAIN- MAKE A HABIT OF MAINTAINING THE CORRECT
PROCEDURE.
SAMPLING PLANS
SAMPLING PLANS MAY BE GROUPED INTO
THREE CATEGORIES:-
1-SINGLE SAMPLING PLAN
2-DOUBLE SAMPLING PLAN
3-MULTIPLE SAMPLING PLAN
SINGLE SAMPLING PLAN
WHEN A DECISION ON ACCEPTANCE OR
REJECTION OF THE LOT IS MADE ON THE BASIS
OF ONLY ONE SAMPLE, THE ACCEPTANCE PLAN
IS KNOWN AS A SINGLE SAMPLING PLAN.
IN A SINGLE SAMPLING PLAN
THREE NUMBERS ARE SPECIFIED.
SINGLE SAMPLING PLAN
N= LOT SIZE, FROM WHICH THE SAMPLE IS
DRAWN.
n= SAMPLE SIZE
c= acceptance number
SINGLE SAMPLING PLAN
IF A SAMPLING PLAN IS
N = 50
n = 5
c = 1
SINGLE SAMPLING PLAN
IT MEANS, TAKE A SAMPLE OF 5 ITEMS FROM A
LOT OF 50, IF THE SAMPLE CONTAINS MORE
THAN 1 DEFECTIVE REJECT THE LOT, OTHERWISE
ACCEPT THE LOT.
SINGLE SAMPLING PLAN
INSPECT A SAMPLE OF n PIECES
IF NUMBER OF DEFECTIVES
DOES NOT EXCEED ‘c’ EXCEED ‘c’
ACCEPT THE LOT REJECT THE LOT
DOUBLE SAMPLING PLAN
IN DOUBLE SAMPLING PLAN, HE DECISION ON
ACCEPTANCE OR REJECTION AT ONCE IF THE
FIRST SAMPLE IS GOOD ENOUGH OR REJECTED
AT ONCE IF THE FIRST SAMPLE IS BAD ENOUGH.
IF THE FIRST SAMPLE IS NEITHER GOOD
ENOUGH NOR BAD ENOUGH, THE DECISION IS
BASED ON THE EVIDENCE OF FIRST AND
SECOND SAMPLE COMBINED.
DOUBLE SAMPLING PLAN
PARAMETERS:-
n1 = NUMBER OF PIECES IN THE FIRST SAMPLE.
c1 = ACCEPTANCE NUMBER FOR THE FIRST
SAMPLE
i.e. THE MAX NUMBER OF DEFECTIVES THAT
WILL PERMIT THE ACCEPTANCE OF THE LOT ON
THE BASIS OF THE FIRST SAMPLE.
DOUBLE SAMPLING PLAN
n2 = NUMBER OF PIECES IN THE SECOND
SAMPLE.
n1+n2 = NUMBER OF SAMPLE IN THE TWO
SAMPLES COMBINED.
c2 = ACCEPTANCE NUMBER OF THE TWO
SAMPLES COMBINED.
DOUBLE SAMPLING PLAN
i.e. THE MAX NUMBER OF DEFECTIVES THAT
WILL PERMIT THE ACCEPTANCE OF THE LOT ON
THE BASIS OF THE FIRST AND SECOND
COMBINED.
DOUBLE SAMPLING PLAN
INSPECT n1 PIECES
ZZ
IF THE NO. OF DEFECTIVES
DOES NOT EXCEED c1 c2<def.<_c1 EXCEEDS c2
ACCEPT THE LOT TAKE SECOND SAMPLE REJECT THE LOT
OF n2 PIECES
DOUBLE SAMPLING PLAN
NO. OF DEFECTIVES IN THE FIRST AND SECOND
SAMPLES COMBINED i.e. IN (n1+n2)
DOES NOT EXCEED c2 EXCEED c2
ACCEPT THE LOT REJECT THE LOT

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Quality CONTROL BY PIYUSH GUPTA

  • 2. WHAT IS QUALITY “THE ABILITY OF YOUR PRODUCT OR SERVICE TO SATISFY YOUR CUSTOMERS.”
  • 3.
  • 4. SEVEN QC TOOLS THE SEVEN BASIC TOOLS OF QUALITY IS A DESIGNATION GIVEN TO A FIXED SET OF GRAPHICAL TECHNIQUES IDENTIFIED AS BEING MOST HELPFUL IN TROUBLESHOOTING ISSUES RELATED TO QUALITY. THIS TECHNIQUE IS USED TO SOLVE THE VAST MAJORITY OF QUALITY- RELATED ISSUES.
  • 5. WHAT ARE SEVEN QC TOOLS THEY ARE THE FOLLOWING SEVEN TOOLS. 1.PARETO CHART 2.CAUSE AND EFFECT DIAGRAM 3.CHECK SHEET 4.FLOW CHART 5.HISTOGRAM 6.SCATTER DIAGRAM 7.CONTROL CHART
  • 6. PARETO CHART IN PARETO CHART, THE VERTICAL AXIS REPRESENTS PROPORTION, AND THE HORIZONTAL AXIS REPRESENTS ITEMS.BAR GRAPS REPRESENTING THE ITEMS ARE SORTED FROM THE LEFT IN DESCENDING ORDER IN TERMS OF THE VALUES. IN ADDITION, THE CUMULATIVE FREQUENCY DISTRIBUTION CURVE, A LINE CONNECTING THE CUMULATIVE PERCENTAGES UP TO EACH ITEMS) IS ALSO DRAWN. THE PURPOSE OF THE PARETO CHART IS TO HIGHLIGHT THE MOST IMPORTANT AMONG A (TYPICALLY LARGE) SET OF FACTORS. IN QUALITY CONTROL,
  • 7.
  • 8. CAUSE AND EFFECT DIAGRAM COMMON USES OF CAUSE AND EFFECT DIAGRAM ARE PRODUCT DESIGN AND QUALITY DEFECT PREVENTION. THE OTHER NAME IS FISHBONE DIAGRAM.
  • 9. • PEOPLE: ANYONE INVOLVED WITH THE PROCESS • METHODS: HOW THE PROCESS IS PERFORMED AND THE SPECIFIC REQUIREMENTS FOR DOING IT, SUCH AS POLICIES, PROCEDURES, RULES, REGULATIONS AND LAWS • MACHINES: ANY EQUIPMENT, COMPUTERS, TOOLS, ETC. REQUIRED TO ACCOMPLISH THE JOB • MATERIALS: RAW MATERIALS, PARTS, PENS, PAPER, ETC. USED TO PRODUCE THE FINAL PRODUCT • MEASUREMENTS: DATA GENERATED FROM THE PROCESS THAT ARE USED TO EVALUATE ITS QUALITY • ENVIRONMENT: THE CONDITIONS, SUCH AS LOCATION, TIME, TEMPERATURE, AND CULTURE IN WHICH THE PROCESS OPERATES CAUSES ARE USUALLY GROUPED INTO MAJOR CATEGORIES TO IDENTIFY THESE SOURCES OF VARIATION. THE CATEGORIES TYPICALLY INCLUDE:
  • 10. CAUSE AND EFFECT DIAGRAM
  • 11. FLOW CHART A FLOWCHART IS A TYPE OF DIAGRAM THAT REPRESENTS AN ALGORITHM, WORKFLOW OR PROCESS, SHOWING THE STEPS AS BOXES OF VARIOUS KINDS, AND THEIR ORDER BY CONNECTING THEM WITH ARROWS. FLOWCHARTS ARE USED IN ANALYZING, DESIGNING, DOCUMENTING OR MANAGING A PROCESS OR PROGRAM IN VARIOUS FIELDS
  • 13. CHECK SHEET • CHECK SHEET IS A TABLE THAT LISTS CHECK ITEMS TO FACILITATE INSPECTIONS.
  • 14. CHECK SHEET CHECK SHEETS TYPICALLY EMPLOY A HEADING THAT ANSWERS THE FIVE WS: • WHO FILLED OUT THE CHECK SHEET • WHAT WAS COLLECTED (WHAT EACH CHECK REPRESENTS, AN IDENTIFYING BATCH OR LOT NUMBER) • WHERE THE COLLECTION TOOK PLACE (FACILITY, ROOM, APPARATUS) • WHEN THE COLLECTION TOOK PLACE (HOUR, SHIFT, DAY OF THE WEEK) • WHY THE DATA WERE COLLECTED
  • 16. HISTROGRAM HISTROGRAM REPRESENTS THE DISTRIBUTION OF DATA BY USING BAR GRAPH. THE VERTICAL AXIS REPRESENTS THE FREQUENCY , AND THE HORIZONTAL AXIS REPRESENTS BINS OF DATA. IT IS ALSO CALLED A FREQUENCY DISTRIBUTION CHART. A HISTOGRAM IS A GRAPHICAL REPRESENTATION OF THE DISTRIBUTION OF DATA.
  • 18. SCATTER DIAGRAM SCATTER DIAGRAM IS A DIAGRAM IN WHICH DATA OF TWO ITEMS ARE PLOTTED.
  • 19. CONTROL CHARTS CONTROL CHARTS SHOWN THE TREND OF AN ITEM AND INDICATES WHETHER THE ITEM IS UNDER CONTROL OR NOT. WE CAN CONCLUDE THAT THE ITEM IS UNDER CONTROL AS LONG AS THE VALUES STAY BETWEEN THE UPPER CONTROL LIMIT(UCL) AND LOWER CONTROL LIMIT(LCL), ALLOWING THE VARIANCE TO A CERTAIN EXTENT.
  • 21. QUALITY CIRCLE A QUALITY CIRCLE IS A GROUP OF WORKERS WHO DO THE SAME OR SIMILAR WORK(USUALLY 3 TO 12 EMPLOYEES) WHO MEET REGULARLY TO IDENTIFY, ANALYZE AND SOLVE WORK-RELATED PROBLEMS. THESE MAY CONCERN QUALITY, PRODUCTIVITY, SAFETY, JOB STRUCTURE, PROCESS FLOW, CONTROL MECHANISM, AESTHETICS OF THE WORK AREA .
  • 22. QUALITY CIRCLE QUALITY CIRCLE IS A PARTICIPATIVE MANAGEMENT SYSTEM IN WHICH WORKERS MAKE SUGGESTIONS AND IMPROVEMENTS FOR THE BETTERMENT OF ORGANIZATIONS.
  • 24. CONCEPT OF QUALITY CIRCLE THE QC CONCEPT HAS THREE MAJOR ATTRIBUTES THESE ARE: 1- QC IS A FORM OF PARTICIPATIVE MANAGEMENT. 2- QC IS A HUMAN RESOURCE DEVELOPMENT TECHNIQUE. 3- QC IS A PROBLEM SOLVING TECHNIQUE.
  • 25. CHARACTERISTICS OF QC THE CHARACTERISTICS OF QC AS MANAGEMENT TOOL FOR IMPROVING PRODUCTIVITY AND QUALITY MAY BE LISTED AS BELOW: 1- QC ARE SMALL PRIMARY GROUPS OF EMPLOYEES/WORKERS WHOSE LOWER LIMIT IS 3 AND UPPER LIMIT IS 12.
  • 26. QUALITY CIRCLE 2- THE MEMBERSHIPS OF QC ARE MOST VOLUNTORY. THE WORKERS/EMPLOYEES INTERESTED IN SOME AREA OF WORK IMPROVEMENT MAY COME TOGETHER TO FORM A CIRCLE. 3- EACH CIRCLE IS LED BY THE AREA SUPERVISOR. ALSO THEY ARE NORMALLY CO-ORDINATED CENTRALLY IN ORGANIZATION BY A PERSON WHO HAS BEEN TRAINED AS A FACILITATOR.
  • 27. QUALITY CIRCLE 4-THE MEMBERS MEET REGULARLY EVERY WEEK OR ACCORDING TO AN AGREED SCHEDULE. 5- THE CIRCLE MEMBERS ARE SPECIALLY TRAINED IN TECHNIQUES OF ANALYSIS AND PROBLEM SOLVING IN ORDER TO PLAY THEIR ROLE EFFECTIVELY. 6- THE BASIC ROLE OF CIRCLE IS TO IDENTIFY AND SOLVE WORK RELATED PROBLEMS FOR IMPROVING QUALITY AND PRODUCTIVITY.
  • 28. ADVANTAGE OF QC 1-PROMOTE HIGH LEVEL OF PRODUCTIVITY AND QUALITY MINDEDNESS. 2-SELF AND MUTUAL DEVELOPMENT OF EMPLOYEES. 3-CREATING TEAM SPIRIT AND UNITY OF ACTION. 4-INCREASED MOTIVATION, JOB SATISFACTION AND PRIDE IN THEIR WORK.
  • 29. ADVANTAGE OF QC 5- REDUCED ABSENTEESISM AND LABOUR TURNOVER. 6-WASTE REDUCTION. 7-COST REDUCTION. 8-IMPROVED COMMUNICATION. 9-SAFETY IMPROVEMENT. 10-TRAINED STAFF. 11-LEADERSHIP DEVELOPMENT. 12-IDENTIFY WORK RELATED PROBLEM AND SOLVES THEM EFFECTIVELY
  • 30. QUALITY MANAGEMENT QM ENSURES THAT AN ORGANIZATION PRODUCT OR SERVICE IS CONSISTANT. IT HAS FOUR MAIN COMPONENTS:- 1-QUALITY PLANNING 2- QUALITY CONTROL 3- QUALITY ASSURANCE 4- QUALITY IMPROVEMENT
  • 31. QUALITY MANAGEMENT QUALITY MANAGEMENT IS FOCUSED NOT ONLY ON PRODUCT AND SERVICE QUALITY BUT ALSO ON TO MEANS TO ACHIEVE IT. QUALITY MANAGEMENT, THEREFORE USES QUALITY ASSURANCE AND CONTROL OF PROCESSES AS WELL AS PRODUCTS TO ACHIEVE MORE CONSISTENT QUALITY.
  • 33. PDCA PDCA (PLAN–DO–CHECK–ACT OR PLAN–DO– CHECK–ADJUST) IS AN ITERATIVE FOUR-STEP PROBLEM SOLVING TYPICALLY USED IN QUALITY CONTROL. IT IS ALSO KNOWN AS DEMING CYCLE. IT IS FOUR-STEP MANAGEMENT METHOD USED IN BUSINESS FOR THE CONTROL AND CONTINUOUS IMPROVEMENT OF PROCESSES AND PRODUCTS. IT IS ALSO KNOWN AS THE DEMING CIRCLE.
  • 35. THE FOUR PHASES IN THE PLAN-DO- CHECK-ACT CYCLE INVOLVE: PLAN: SET GOALS BASED ON CUSTOMER NEEDS. DO: IMPLEMENT THE PLAN AND MEASURE ITS PERFORMANCE. CHECK: ANALYZE WHAT HAPPENED ACT: MAKE SURE IMPROVEMENT IS PERMANENT
  • 36. BENEFITS OF THE PDCA CYCLE 1-PROBLEM SOLVING PROCESS 2-CONTINUOUS IMPROVEMENT 3-HUMAN RESOURCES DEVELOPMENT 4-NEW PRODUCT DEVELOPMENT 5-PROCESS TRAILS 6-PROJECT MANAGEMENT 7-DAILY ROUTINE MANAGEMENT FOR THE INDIVIDUAL AND OR THE TEAM
  • 37. COST OF QUALITY THE COSTS OF CARRYING OUT THE COMPANY QUALITY FUNCTIONS(MEETING THE QUALITY NEEDS OF THE CUSTOMERS) ARE KNOWN AS COSTS OF QUALITY. THESE INCLUDES: 1- MARKET RESEARCH COSTS OF DISCOVERING THE QUALITY NEEDS OF THE CUSTOMERS. 2-THE PRODUCT RESEARCH AND DEVELOPING COST.
  • 38. COST OF QUALITY 3-THE DESIGN AND MANUFACTURING COST. 4-COST OF INSPECTION AND TEST. 5-COST OF DEFECT PREVENSION. 6-COST OF SCRAP, QUALITY FAILURE. 7-COST OF QUALITY ASSURANCE.
  • 39. THE QUALITY COSTS BE DEFINED IN FOUR CATEGORIES: 1- COST OF PREVENTION 2- COST OF APPRAISAL 3-COST OF INTERNAL FAILURES 4-COST OF EXTERNAL FAILURES
  • 42. COST OF PREVENTION 1- COST OF QUALITY PLANNING 2- COST OF DOCUMENTING 3- PROCESS CONTROL COST 4- QUALITY EDUCATION AND TRANNING 5- QUALITY IMPROVEMENT PROJECTS
  • 43. COST OF APPRAISAL • TEST AND INSPECTION OF PURCHASED MATERIALS • ACCEPTANCE TESTING • CHECKING LABOR • SETUP FOR TEST OR INSPECTION • TEST AND INSPECTION EQUIPMENT • QUALITY AUDITS
  • 44. COST OF INTERNAL FAILURE • SCRAP • REWORK
  • 45. COST OF EXTERNAL FAILURE • COMPLAINTS IN WARRANTY • COMPLAINTS OUT OF WARRANTY • PRODUCT SERVICE • PRODUCT LIABILITY • PRODUCT RECALL • LOSS OF REPUTATION
  • 46. QUALITY ASSURANCE QUALITY ASSURANCE (QA) IS A WAY OF PREVENTING MISTAKES OR DEFECTS IN MANUFACTURED PRODUCTS AND AVOIDING PROBLEMS WHEN DELIVERING SOLUTIONS OR SERVICES TO CUSTOMERS. WHICH ISO 9000 DEFINES AS "PART OF QUALITY MANAGEMENT FOCUSED ON PROVIDING CONFIDENCE THAT QUALITY REQUIREMENTS WILL BE FULFILLED
  • 47. QUALITY ASSURANCE QUALITY ASSURANCE MEANS ENSURING CONFIRMETTING OF THE QUALITY TO THE REQUIRED BASIC SPECIFICATION OR GIVEN NEEDS. THE STAGE IN CONSIDERATION OF TOTAL QUALITY OF PRODUCT RELATED TO QUALITY ASSURANCE-
  • 48. QUALITY ASSURANCE 1- DESIGN STAGE 2-MANUFACTURING STAGE 3-FIELD OBSERVATION
  • 49. QUALITY ASSURANCE 1-DESIGN STAGE-TO ENSURE THAT THE QUALITY OF DESIGN IS ACCORDING TO THE NEEDS OF THE CUSTOMERS. 2-MANUFACTURING STAGE-TO CHECK WHETHER THE QUALITY OF PRODUCTS MANUFACTURED CONFORMS TO THE DESIGN SPECIFICATIONS.
  • 50. QUALITY ASSURANCE 3-FIELD OBSERVATION- RELIABILITY AND PERFORMANCE ANALYSIS.
  • 51. FUNCTION OF QUALITY ASSURANCE 1- PROCESSING OF FIELD COMPLAINTS. 2- QUALITY RATING OF OUT GOING PRODUCTS. 3- QUALITY SURVEY OR AUDIT. 4-PREPARATION OF EXECUTIVE REPORT ON QUALITY. 5- SETTING UP QUALITY LEVEL INSPECTION PLANNING. 6- DISPOSITION OF NON- CONFIRMING PRODUCT.
  • 52. ADVANTAGE OF QUALITY ASSURANCE 1- FEWER DEFECTS 2- LESS SCRAP 3- BETTER QUALITY 4-GOOD CUSTOMER RELATION. 5- HIGHER PRODUCTIVITY. 6-LESS INSPECTION REFLECT.
  • 53. 6 SIGMA SIX SIGMA IS A SET OF TECHNIQUES AND TOOLS FOR PROCESS IMPROVEMENT. IT WAS DEVELOPED BY MOTOROLA IN 1986. SIX SIGMA SEEKS TO IMPROVE THE QUALITY OF PROCESS OUTPUTS BY IDENTIFYING AND REMOVING THE CAUSES OF DEFECTS (ERRORS) AND MINIMIZING VARIABILITY IN MANUFACTURING AND BUSINESS PROCESSES. IT USES A SET OF QUALITY MANAGEMENT METHODS.
  • 54. 6 SIGMA EACH SIX SIGMA PROJECT CARRIED OUT WITHIN AN ORGANIZATION FOLLOWS A DEFINED SEQUENCE OF STEPS AND HAS QUANTIFIED VALUE TARGETS, FOR EXAMPLE REDUCE PROCESS CYCLETIME, REDUCE POLLUTION, REDUCE COSTS, INCREASE CUSTOMER SATISFACTION AND INCREASE PROFIT.
  • 55. 6 SIGMA THERE ARE TWO SIX SIGMA PROCESSES- 1-DMAIC PROCESS 2-DMADV PROCESS
  • 56. DMAIC PROCESS DMAIC IS USED FOR PROJECTS AIMED AT IMPROVING AN EXISTING BUSINESS PROCESSES.
  • 58. DMAIC PROCESS THE DMAIC PROJECT METHODOLOGY HAS FIVE PHASES: 1-DEFINE- * DEFINE THE PROJECT PURPOSE AND SCOPE. *IDENTIFY HIGH LEVEL PROCESSES FOR IMPROVEMENT. * DETERMINE CUSTOMER NEEDS AND BENEFITS.
  • 59. DMAIC PROCESS 2-MEASURE- *IDENTIFY THE GAP BETWEEN CURRENT AND REQUIRED PERFORMANCE. *IDENTIFY POTENTIAL AREAS FOR IMPROVEMENTS. *PINPOINT PROBLEMS LOCATIONS AND OCCURRENCES.
  • 60. DMAIC PROCESS 3-ANALYZE- • IDENTIFY ROOT CAUSES AND VALIDATE ROOT CAUSES AGAINST CAPTURED DATA. • DETERMINE IMPROVEMENTS THAT NEEDS TO BE MADE.
  • 61. DMAIC PROCESS 4-IMPROVE- IMPROVE OR OPTIMIZE THE CURRENT PROCESS BASED UPON DATA ANALYSIS USING TECHNIQUES SUCH AS DESIGN OF EXPERIMENTS, POKA YOKE OR MISTAKE PROOFING.
  • 62. DMAIC PROCESS 5-CONTROL- • PERFORM BEFORE AND AFTER ANALYSIS. • DOCUMENTS RESULTS AND DETERMINE NEXT STEP RECOMMENDATIONS.
  • 63. DMADV PROCESS DMADV IS USED FOR NEW PROJECTS OR NEW BUSINESS PROCESS.
  • 65. DMADV PROCESS THE DMAIC PROJECT METHODOLOGY HAS FIVE PHASES: 1-DEFINE- DEFINE THE PROJECT GOAL AND CUSTOMER( INTERNAL AND EXTERNAL DELIVERABLES. 2-MEASURE- MEASURE AND DETERMINE CUSTOMER NEEDS AND SPECIFICATIONS.
  • 66. DMADV PROCESS 3-ANALYZE- ANALYZE THE PROCESS OPTIONS TO MEET THE CUSTOMER NEEDS. 4-DESIGN- DESIGN THE PROCESS TO MEET THE CUSTOMER NEEDS. 5-VERIFY- VERIFY THE DESIGN PERFORMANCE AND ABILITY TO MEET CUSTOMER NEEDS.
  • 67. JIT(JUST-IN-TIME) J-I-T IS AN APPROACH THAT SEEKS TO ELIMINATES ALL SOURCES OF WASTE IN PRODUCTION ACTIVITIES BY PROVIDING THE RIGHT PART AT RIGHT PLACE AT THE RIGHT TIME
  • 68. BENEFITS OF JIT 1-REDUCTION IN INVENTORY 2-IMPROVED QUALITY 3-REDUCED SPACE REQUIREMENTS 4-SHORTER LEAD TIMES 5-LOWER PRODUCTION COSTS 6-INCREASED PRODUCTIVITY 7-INCREASED MACHINE UTILIZATION 8-GREATER FLEXIBILITY
  • 69.
  • 70. POKA-YOKE ‘POKA’ : MISTAKE ‘YOKE’ : PROOFING • A POKA-YOKE IS ANY MECHANISM IN A LEAN MANUFACTURING PROCESS THAT HEALPS AN EQUIPMENT, OPERATOR AVOID(YOKE) MISTAKES(POKA). • ITS PURPOSE IS TO ELIMINATE PRODUCT DEFECTS BY PREVENTING, CORRECTING AND DRAWING ATTENTION TO HUMAN ERRORS AS THEY OCCUR.
  • 71. POKA-YOKE • THE CONCEPT WAS FORMALIZED AND THE TERM ADOPTED BY SHIGEO SHINGO(JAPANESE INDUSTRIAL ENGINEER) AS PART OF THE TOYOTA PRODUCTION SYSTEM.
  • 72. POKA-YOKE • THIS TOOL CAN BE APPLIED TO ANY PROCESS, BE IT IN MANUFACTURING OR THE SERVICE INDUSTRY.
  • 74. BENEFITS OF POKA-YOKE • ELIMINATION OF SET-UP ERRORS AND IMPROVED QUALITY • DECREASED SET-UP TIMES WITH ASSOCIATED REDUCTION IN PRODUCTION TIME AND IMPROVED PRODUCTION CAPACITY • SIMPLIFIED AND IMPROVED HOUSEKEEPING • INCREASED SAFETY • LOWER COSTS • LOWER SKILL REQUIREMENTS • INCREASED PRODUCTION FLEXIBILITY • IMPROVED OPERATOR ATTITUDES.
  • 75. THE 5S SYSTEM 5S IS A BASIC, FUNDAMENTAL, SYSTEMATIC APPROACH FOR PRODUCTIVITY, QUALITY AND SAFETY IMPROVEMENT IN ALL TYPES OF BUSINESS. THE 5S ARE:- 1-SORT 2-SET IN ORDER 3-SHINE 4-STANDARIZE 5-SUSTAIN
  • 76. THE 5S SYSTEM 1-SORT- ELIMINATE UNNECESSARY ITEMS FROM THE WORKPLACE. 2-SET IN ORDER- ARRANGE ITEMS SO THAT THEY ARE EASY TO USE, FIND AND PUT AWAY. 3-SHINE- KEEP THE ITEMS AND WORK AREA NEAT AND CLEAN. 4-STANDARDIZE- CREATE A CONSISTENT APPROACH TO TASKS AND PROCEDURES. 5-SUSTAIN- MAKE A HABIT OF MAINTAINING THE CORRECT PROCEDURE.
  • 77. SAMPLING PLANS SAMPLING PLANS MAY BE GROUPED INTO THREE CATEGORIES:- 1-SINGLE SAMPLING PLAN 2-DOUBLE SAMPLING PLAN 3-MULTIPLE SAMPLING PLAN
  • 78. SINGLE SAMPLING PLAN WHEN A DECISION ON ACCEPTANCE OR REJECTION OF THE LOT IS MADE ON THE BASIS OF ONLY ONE SAMPLE, THE ACCEPTANCE PLAN IS KNOWN AS A SINGLE SAMPLING PLAN. IN A SINGLE SAMPLING PLAN THREE NUMBERS ARE SPECIFIED.
  • 79. SINGLE SAMPLING PLAN N= LOT SIZE, FROM WHICH THE SAMPLE IS DRAWN. n= SAMPLE SIZE c= acceptance number
  • 80. SINGLE SAMPLING PLAN IF A SAMPLING PLAN IS N = 50 n = 5 c = 1
  • 81. SINGLE SAMPLING PLAN IT MEANS, TAKE A SAMPLE OF 5 ITEMS FROM A LOT OF 50, IF THE SAMPLE CONTAINS MORE THAN 1 DEFECTIVE REJECT THE LOT, OTHERWISE ACCEPT THE LOT.
  • 82. SINGLE SAMPLING PLAN INSPECT A SAMPLE OF n PIECES IF NUMBER OF DEFECTIVES DOES NOT EXCEED ‘c’ EXCEED ‘c’ ACCEPT THE LOT REJECT THE LOT
  • 83. DOUBLE SAMPLING PLAN IN DOUBLE SAMPLING PLAN, HE DECISION ON ACCEPTANCE OR REJECTION AT ONCE IF THE FIRST SAMPLE IS GOOD ENOUGH OR REJECTED AT ONCE IF THE FIRST SAMPLE IS BAD ENOUGH. IF THE FIRST SAMPLE IS NEITHER GOOD ENOUGH NOR BAD ENOUGH, THE DECISION IS BASED ON THE EVIDENCE OF FIRST AND SECOND SAMPLE COMBINED.
  • 84. DOUBLE SAMPLING PLAN PARAMETERS:- n1 = NUMBER OF PIECES IN THE FIRST SAMPLE. c1 = ACCEPTANCE NUMBER FOR THE FIRST SAMPLE i.e. THE MAX NUMBER OF DEFECTIVES THAT WILL PERMIT THE ACCEPTANCE OF THE LOT ON THE BASIS OF THE FIRST SAMPLE.
  • 85. DOUBLE SAMPLING PLAN n2 = NUMBER OF PIECES IN THE SECOND SAMPLE. n1+n2 = NUMBER OF SAMPLE IN THE TWO SAMPLES COMBINED. c2 = ACCEPTANCE NUMBER OF THE TWO SAMPLES COMBINED.
  • 86. DOUBLE SAMPLING PLAN i.e. THE MAX NUMBER OF DEFECTIVES THAT WILL PERMIT THE ACCEPTANCE OF THE LOT ON THE BASIS OF THE FIRST AND SECOND COMBINED.
  • 87. DOUBLE SAMPLING PLAN INSPECT n1 PIECES ZZ IF THE NO. OF DEFECTIVES DOES NOT EXCEED c1 c2<def.<_c1 EXCEEDS c2 ACCEPT THE LOT TAKE SECOND SAMPLE REJECT THE LOT OF n2 PIECES
  • 88. DOUBLE SAMPLING PLAN NO. OF DEFECTIVES IN THE FIRST AND SECOND SAMPLES COMBINED i.e. IN (n1+n2) DOES NOT EXCEED c2 EXCEED c2 ACCEPT THE LOT REJECT THE LOT

Editor's Notes

  1. GH