This document discusses quality assurance in manufacturing. It defines quality as producing consistent products that meet customer expectations. Quality assurance is described as a process that ensures quality policies are followed and final product acceptance. It should be independent and have management support. Ensuring safety and meeting customer expectations are also discussed. The role of quality assurance in manufacturing is to systematically prevent defects and ensure products meet specifications. Quality should be built into products through things like manufacturing travelers, procedures, and inspections. Two case studies provide examples of quality assurance methods for resin infusion and using software to unify quality assurance processes for a semiconductor company.

1. QUALITY ASSURANCE IN MANUFACTURING
INDUSTRY
Submitted by-
Rishabh Jain (K11619)
B.Tech Mechanical
6th Sem./ 3rd Yr

2. Contents
• Quality
• Quality Assurance
• Support
• Safety
• Customer expectations
• Statistically based process
• Role of Quality Assurance in manufacturing
• Building quality into the product
• Manufacturing travelers
• Case Study- 1
• Case Study- 2

3. What is Quality ?
• The ability to make the same thing the same way, over
and over again
• Customer buys today is same as what they bought last
week or will buy next week
• Product meets customer’s expectations 100% of the
time

4. 4
Quality Assurance
• A process, not an end-point
• Must be independent of financial pressures
• Must ensure that quality policies are followed
• Must have final authority in product acceptance,
rejection and release to public
• Integral to production, not an add-on
• Responsible for day-to-day operations and for longer
term goal settings
• Quantitative discipline with specified parameters

5. Support
• Top management must buy into what QA is doing
• QA manager must report to CEO or direct link
• Corporate support does not always make one popular
with local managers but is critical for maintaining high
quality standards

6. Safety
• Conflicts may exist between optimum quality and food
safety
• Manufacturers must recognize that many processes
that ensure food safety do not enhance product quality
• Any time a process change occurs to improve quality,
product safety requires re-verification
• Responsibility may fall to QA

7. Customer expectations
• This is where quality programs begin.
– Marketing has defined the customer expectations.
– Product development has created a product that meets those
expectations.
– Engineering has designed a process to make the desired
product.
– Now, all QA must do is design a control system that verifies
that everything is working as designed.

8. Statistically based process
• You cannot inspect quality in.
• The process must be able to meet the specifications or
there will be a lot of rework.
• Programs have to be statistically based.
• There must be integration between R&D, engineering
and marketing to define a product that can be made
99% of the time.
• The program that is designed to control the process
must then make sense.

9. • Increased Customer Satisfaction
• Reduced waste
• Reduced costs
• Increased sales and market share
• Increased market orientation
All resulting in a 'world class' business
Benefits of Quality Assurance

10. Role of Quality Assurance in Manufacturing
• Provide a systematic and proactive approach for preventing defects
• Implement procedures that ensure manufactured products consistently meet
the required quality specifications
• Incorporate the QA requirements into the manufacturing traveler
• Perform audits to ensure:
•Established procedures are being followed
•Personnel performing the work are adequately trained
•Equipment is calibrated and in good repair

11. Build Quality Into The Product
Successful manufacturers build quality into their
products
• The quality necessary to achieve the required specification is designed
and planned into the product upfront – it than becomes integrated into
the manufacturing methods used to produce the product
• This is accomplished through the use of manufacturing travelers,
documented procedures, inspection and test plans, engineered tooling
and fixtures, and continuous improvement

12. Manufacturing Travelers
•Sequential listing of required tasks
•References special work instructions and procedures
•Incorporates in-process inspection and test requirements
•Captures individual part data (actual measurements & test results)
•Provides hold points that require approval prior to proceeding
•Historical record for each individual item produced
•Provides consistency from part to part throughout the production
run

13. CASE STUDY- 1
Quality Assurance & Quality Control
Methods For Resin Infusion

14. PROBLEM
The primary aim of this case study was to aid composite manufacturers by identifying resin infusion quality assurance
and quality control (QA/QC) issues and identifying appropriate QA/QC practices. The resin infusion issues were
identified through an in depth investigation into the technical literature surrounding the relatively new process. The key
defects found in resin infusion are
(1) voids and dry spots;
(2) thickness and fiber volume fraction variations;
(3) resin curing problems;
(4) fiber orientation issues;
(5) delaminations; and
(6) (6) secondary bonding issues.

15. A level three degree of quality
assurance implementation would
be appropriate for products
where the resin infusion process
is replacing the pre-
preg/autoclave process. This
level has traditionally been
reserved for aerospace
components, but could be
expanded to include
infrastructure, defense, and any
products for which failure could
result in loss of life.
A level one degree of quality
assurance implementation would be
appropriate for all components
which do not need to meet
particularly exacting requirements
and which would result in minor
repair costs and no chance of
human injury as consequence of
failure. These products include
some marine products, most
consumer goods, and some
construction/architectural
applications
A level two degree of quality
assurance implementation would
be appropriate for all other high
performance products which do
not have a high consequence of
failure. This level encapsulates
the majority of the yacht
production in Maine. Most wind
energy components, certain
corrosion resistant products, and
some consumer goods products
would fall into this category.
SOLUTION
Three expanded levels of quality assurance were build on the recommendations of composite manufacturers

16. CASE STUDY- 2
A Global Semiconductor Leader
Unifies & Accelerates
Product Quality Assurance
Management across the Enterprise

17. PROBLEM
•Siloed quality assurances processes
•Cumbersome spreadsheets
•Complex 8D reports
•Delay in issue resolution and response
•Limited top-level visibility

18. SOLUTION
•Quality issue recording
•Initial verification & failure analysis
•Integrated data management
•Reports & Dashboards

19. THANK YOU