Quality Control Report

QUALITY CONTROL SYSTEM FOR TUCKSIN ENGINEERING SDN. BHD.
A PROJECT REPORT
Submitted by
NELSON DAVID BASSEY (I14005232)
ZIM CHIDERA EZEVILLO (I12002112)
EKO PRATAMA
DANNY GOH SHIN TECK
NWAFOR IKECHUKWU
In partial fulfillment of the award of the degree
Of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
FACULTY OF SCIENCE, TECHNOLOGY, ENGINEERING AND MATHEMATICS
INTI INTERNATIONAL UNIVERSITY, NILAI
NOVEMBER 2015

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QUALITY CONTROL SYSTEM FOR TCKSIN ENGINEERING SDN. BHD.
Abstract
Over the years, technological advancements have ensured that businesses have had to evolve
to be more efficient in terms of productivity and client satisfaction. Quality control has
become a very important tool in measuring and improving the performance of a company.
TSG has made a name for itself as a manufacturing company that meets the needs of its
clients in a timely and efficient manner.
For this project, we have used the Total Quality Management (TQM) method. This method is
an adaptation of the Statistical Quality Control (SQC), which was created by Fredrick W.
Taylor in his book titled Principles of Scientific Management. The use of this method can be
traced back the mid 1920’s at the Western Electric plant of the Bell system. The current
variations of the TQM currently in use were created by Edward Deming and Joseph Juran.
This project focuses on creating a system based on TQM for TSG to use to measure and
adequately control quality in their manufacturing process. We have decided to focus only in
two of the services that are rendered by the company which are Design and Fabrication. We
have based our system on five areas of Measurement: Fabrication process measurement, Key
Design Performance areas, Compliance measurement, Efficiency Management, Design
Process Measurement.
This design project will last for the duration of fourteen weeks (one semester). This is a group
project, and we must work together to complete the tasks. Time management, team
management, and good planning are part of the learning outcomes of this project.

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ACKNOWLEDGEMENTS
As a token of gratitude to all who directly and indirectly contributed to the success of
this project, we would like to thank the following people.
We would like to express our special thanks to Tucksin Engineering Sdn. Bhd. as well
as Mr. Gerald Victor for giving us the opportunity to do this wonderful project and also for
giving us his years of experience and expertise in simple advises towards our project.
Thanks to our fellow colleagues who assisted us with transportation and other
logistics in support of our project work. Thank you and God bless you.

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STUDENT’S DECLARATION
We declare that this project report titled “QUALITY CONTROL SYSTEM FOR
TUCKSIN ENGINEERING SDN. BHD.” is the result of our own study except as cited in
the references. The report has not been accepted for any degree program and is not
concurrently submitted in candidature of any other degree program.
Signature of Group Leader: ____________________________
Group Leader’s Name: Eko Pratama
Date: November, 2015

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TABLE OF CONTENTS
Page
ABSTRACT i
ACKNOWLEDGEMENT ii
DECLARATION iii
TABLE OF CONTENTS iv
CHAPTER 1: INTRODUCTION
1.1 Project background 6
1.2 Project statement 6
1.3 Objective of project 6
1.4 Project scope 7
1.5 Research overview 7
CHAPTER 2: LITERATURE REVIEW
2.1 Introduction 9
2.2 FMEA 9
2.3 QMS 11
CHAPTER 3: PRODUCT (INTIMaP 1.0 Beta)
3.1 Product background 15
3.2 Product objectives 15
3.3 The Five areas of measurement 15
3.4 Analysis and Measurement 17
CHAPTER 4: RESULT AND DISCUSSION
4.1 TQM Cycle 24

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3.1 CHAPTER 5: CONCLUSION AND RECOMMENDATION
5.1 Conclusions 27
5.2 Recommendation 27
REFERENCES

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CHAPTER 1
INTRODUCTION
1.1 Project Background
Tucksin Engineering is a company headquartered in Malaysia that provides a a full
cycle of design, detailing, fabrication and erection services. The company was
established in 1986 and their area of expertise has expanded to various scopes of
steelworks in industrial and commercial structures.
The current quality measurement process utilized by TSG does not involve the use of
statistical data and an analytical approach. The current method in use by the company is
based on a trial by error approach, which is neither accurate nor precise. This method places a
significant drawback on effectiveness and reliability of output. Our system provides an
avenue for effective data collection and analysis for quality measurement of the entire
manufacturing process at TSG.
1.2 Project Statement
In line with the TSG vision to further establish itself as an approved global supplier in the
various retail industries where it has formed strategic partnerships, this project aims to
develop a Quality Measurement System for the effective measurement and management of
TSG’s manufacturing processes.
1.3 Objective of project
In accomplishing the aim stated above, the primary objectives are as follows:
 Design a system to improve the quality of the entire manufacturing process
 Perform a test to show how to carry out analysis
 Perform a Failure Mode Effect analysis to what corrective measures can be taken
using some common problems that occur in the manufacturing process

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1.4 Project Scope
From the project title that has been chosen, the development of this project must
include representation of the process methodology in free-body diagram and process flow
diagrams. Secondly, a data sheet or specification for following the chosen methodology shall
be included. There is however some guide that must be followed in order to complete this
project.
1.4.1 Literature Review: We researched information from expert inquiry, texts and from
the internet that is related to our project. They include:
i. Quality Measurement systems that are already in use today.
ii. Important factors that affect the quality of the Manufacturing Process.
iii. Research on Total Quality Management (TQM)
1.4.2 Primary Design/Analysis:
i. Created a spreadsheet to enable data entry
ii. Carried out analysis on the results from the data entry using several
statistical tools such as Mean, Range and Standard Deviation.
iii. Performed an FMEA analysis based on our analysis to show the
corrective measures that can be used based on the results that are gotten
from the analysis.
1.4.3 Prototype Fabrication:
a. Materials used:
i. Microsoft Excel

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1.4.4 Report Writing:
i. Progress report was written from the initiation of the work process until
the completion of the project.
ii.
1.5 Project Overview
The following materials and tools were used in the project:
 Microsoft Excel
In our world today, quality control is an aspect of business that has proven to be
invaluable in improving the performance of a company. Quality control is an evaluation that
is needed for corrective responses. Most manufacturers would never think of eliminating the
quality control system from their production processes. Without quality control, the number
of defective products that must be reworked, scrapped or returned would dramatically
increase.
Quality Control helps to regulate and create consistency in products and services,
therefore attracting more clients to a business. It provides a useful tool to judge the
performance of a company in terms of its customer base. In this report, a relationship
between satisfied customers and dissatisfied customers in terms of loyalty will be shown. A
good quality control system helps create an edge in our competitive world while also being
profitable as a result of an increase in sales.

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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
Tuck Sin Engineering Sdn. Bhd. have been in the manufacturing industry for several
years. However up till now, there has not been any system for measuring and
controlling quality within the manufacturing process. So far, they have largely
depended on detecting and fixing issues using a trial by error method. We were
invited to develop a Quality Control System for the company. For our design, we have
chosen to use the TQM (Total Quality Management) method.
2.2 FMEA
Introduction and History
Also called: potential failure modes and effects analysis; failure modes, effects and criticality
analysis (FMECA).
Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all
possible failures in a design, a manufacturing or assembly process, or a product or service.
“Failure modes” means the ways, or modes, in which something might fail. Failures are any
errors or defects, especially ones that affect the customer, and can be potential or actual.
“Effects analysis” refers to studying the consequences of those failures.
Failures are prioritized according to how serious their consequences are, how frequently they
occur and how easily they can be detected. The purpose of the FMEA is to take actions to
eliminate or reduce failures, starting with the highest-priority ones.
Failure modes and effects analysis also documents current knowledge and actions about the
risks of failures, for use in continuous improvement. FMEA is used during design to prevent
failures. Later it’s used for control, before and during ongoing operation of the process.
Ideally, FMEA begins during the earliest conceptual stages of design and continues
throughout the life of the product or service.

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Begun in the 1940s by the U.S. military, FMEA was further developed by the aerospace and
automotive industries. Several industries maintain formal FMEA standards.
What follows is an overview and reference. Before undertaking an FMEA process, learn
more about standards and specific methods in your organization and industry through other
references and training.
FMEA is a qualitative and systematic tool, usually created within a spreadsheet, to help
practitioners anticipate what might go wrong with a product or process. In addition to
identifying how a product or process might fail and the effects of that failure, FMEA also
helps find the possible causes of failures and the likelihood of failures being detected before
occurrence.
Type of FMEA
There are a variety of FMEA; some are used much more often than others. The type of
FMEA’s currently in use are:
 System - focuses on global system functions
 Design - focuses on components and subsystems
 Process - focuses on manufacturing and assembly processes
 Service - focuses on service functions
 Software - focuses on software functions
Why Use FMEA ?
FMEA is designed to assist the engineer improve the quality and reliability of design.
Properly used the FMEA provides the engineer several benefits. Among others, these benefits
include:
 Improve product/process reliability and quality
 Increase customer satisfaction
 Early identification and elimination of potential product/process failure modes
 Prioritize product/process deficiencies
 Capture engineering/organization knowledge
 Emphasizes problem prevention
 Documents risk and actions taken to reduce risk
 Provide focus for improved testing and development
 Minimizes late changes and associated cost
 Catalyst for teamwork and idea exchange between functions

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When to Use FMEA
 When a process, product or service is being designed or redesigned, after quality function
deployment.
 When an existing process, product or services is being applied in a new way.
 Before developing control plans for a new or modified process
 When improvement goals are planned for an existing process, product or service.
 When analyzing failures of an existing process, product or services.
 Periodically throughout the life of the process, product or service.
2.2 Quality Measurement System Importance
QMS is a quality management system is a management technique used to
communicate to employees what is required to produce the desired quality of products and
services and to influence employee actions to complete tasks according to the quality
specifications. The purpose of the Quality Measurement and Analysis is to develop and
sustain a measurement capability used to support management.
With QMS, the company is able to satisfy the customer by achieving or exceeding the
specifications set by the customer. Furthermore QMS is also able to fulfill the organization`s
requirements both internally and externally, and at an optimum cost with efficient use of the
available resources.

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2.2.1 Quality Measurement System Benefits
Figure 1 shows how QMS benefits the company in term of saving time. Before 1996
Numetric Manufacturing Company needs more than 107 weeks to complete the 6 phases of
duration improvement, but by adapting the quality control system, the company can reduce
the duration of the 6 phase, 37 % , to 24,5 weeks just in 3 Years. From this case it is proven
that QMS is giving a positive impact in term of time efficiency

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Figure 2, Second chart above shows that the pink dot is in the low capacity and low
productivity region, and the green dot is in the region of high capacity and productivity. And
the pink color point is when they are lack of regular quality measurement data. The green dot
is when they are adapting the QMS. By this chart we can see that when the company have a
good quality data measurement, they can improve and optimized the capacity and the
productivity of the company.

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Here are some points what are the Benefits of regular Quality Control and Measurement:
- It pushes the company to improve the quality level of their workmanship because of the
pressure of inspections and non-acceptance
- It forces your suppliers to meet your order terms and product requirement, or to compensate
you for any discrepancy ( exact materials, colors, aspect, packing , functions..)
- You don’t discover quality problems after the goods delivered.
- You have the time to adapt your planning and take decisions
- The factory can rework the goods itself and will be more careful in future.
There are some big risks for the company itself if they are lack of quality control and
measurement:
- The shipment cannot be sold at all (too many visual defect, wrong size, dangerous, etc.)
- Products have to be sorted out and reworked in the importing country, at great cost to the
importer.
-The company image suffers because of poor quality delivered to customers

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CHAPTER 3
PRODUCT (INTIMaP 1.0 Beta)
3.1 Product Background
INTIMaP 1.0 is an excel spreadsheet, with tables and formula with makes for a simple
software. The excel platform make it possible for data entry and result/analysis
generation. The system comprises 28 independent parameters across the 5 main areas of
design and fabrication operations.
The current Beta version contains 13 analysis graphs which consists of pie charts, bar
charts, line graphs and histograms for selected parameters. Over time more parameters,
analysis and graphs can be added/plotted as the scope increases, to enhance better process
quality management.
3.2 Product Objectives
i. Generate data on design process
ii. Quantify and qualify errors, needs, areas of concerns and “what should be fixed”
iii. Make easier the assessment of quality problems and root causes.
iv. Enable tracking of impact of changes and corrections in design process.
3.3 The five (5) Areas of Measurement
i. Design process measurement:
This table measures the general operational flow of the design process. The
parameters considered includes the size of projects, clarity of requirements given
by client/customer, lead time (forecasted period for design process to be
completed), the cycle time (actual duration taken for the design to be completed

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including the recalling time), number of errors noticed in the design, errors fixed
after first review process, and the delay time.
ii. Efficiency Management
This table contains parameters which measure how much output is being produced
over a period of time, taking into consideration the number of engineers and hours
put into project. This is also known as “Throughput”. Overall design process
effectiveness has also been considered. The parameters contained in this table
includes: size of project, number of delays on project, causes of delay (qualitative
data measurement), man-hours put into project, number of manufacture rejects
and number of engineers working on project.
iii. Compliance Measurement
A measure of the number of times a design was done outside the guidelines of
normal regulatory compliance rules or requirements by the client and
production/manufacturing plant. These non-compliances need to be fully
documented as to the specific non-compliance time, reasons, and resolutions. The
parameters included in this table include, size of project, reportable naming
corrections in design, reportable miscommunication and stage noticed/reported.

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iv. Key Design Performance Areas
This table contains measures the capability of the design process and engineers
with respect to the overall goals and objectives of the company. Other factors
considered are innovation and out-sources designs and processes.
v. Fabrication Process measurement
This table contains parameters measured over time. With sufficient data, trends
are plotted as a reliable indicator for growth, innovation, and improvement of the
general quality of the company’s product and services.
3.4 Analysis and Results
Using arbitrary data, the following analysis were performed and the graphs plotted.

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3.4.1 Project Distribution by Size:
The Figure below shows both the frequency and percentage project distribution by
size. 3 of all projects handled by the company are major projects, a number which is
equal to that of medium sized projects. From the analysis, only 25% of the company’s
design projects are big projects.
The following table shows the data from the bar graph above was plotted:
3.4.2 Project Distribution by Complexity
The figure below shows the distribution of projects according to level of complexity.
The three levels of complexity are high, medium and low. High level of complexity
requires specialized skills and expertise to perform, while low complexity projects do
not require specialized knowledge and can be performed by an amateur engineer.

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The figure indicates that 4 projects were of high complexity, with 3 of those being
major projects, and 1 a medium sized project. This makes for 75% of high complexity
projects, major projects. None of the projects handled by the company are of low
complexity; therefore by analysis this company should have more skilled design
engineers to maintain quality in its design processes.
3.4.3 Clarity of Requirements by Project Size and Complexity
The table below shows how clear the requirements were for each project. A clear and
detailed requirement will lead to a better design quality, lesser errors and almost zero
delay time. However, a confusing requirement increases on cycle time, errors and
cost.

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From the table above, only 1 highly complex project had clear and detailed
requirement, with 1 confusing requirement. 4 not to complex projects were slightly
clear. By project size, 0 major projects had clear and detailed requirements, with 1
major projects having confusing requirement. According to the data available, this is a
recipe for poor quality output and increased cycle time.
3.4.4 Timeliness and Efficiency of design process
The timeliness of a project is very important to a company. A failure to deliver in due
time can cost the company a fortune, and eventually lose the client or customer.
Paying attention to the graph above is paramount.
This graph shows the deviation of the cycle time from the lead time which indicates
delay time in project. The goal of the quality management process is to reduce this
divergence as much as possible. This can be achieved when the number of errors are
reduced in the design process, and to achieve this, the other graphs would be a great
resource.
3.4.5 Problem-Skill Gap Measure
Understanding the number of errors detected in the designs, when they were returned
to be fixed, and how many were fixed is a good indicator of the competence of the
engineers working on the project. The following line graph shows this information.

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The goal of the design engineers is to match both the number of errors detected with
the number of errors fixed, in the shortest possible time. From the data and result
above, there is a problem-skill gap, however not very much. The wider the gap, the
more critical the conditions. This can be observed from project 2. The gap between
the errors detected and those fixed opened, and the delay time increased significantly.
3.4.6 Trends in Fabrication Process
i. Rejects over time
The line graph above indicates the trends of rejects by the months of the year.
As shown, the months of July and February recorded the highest number of
rejects. The goal of the company is to reduce number over time.

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Over a longer period of time, the progress of the company can be measured.
The bar chart above shows that the company isn’t improving on its effort to
eliminate the number of rejects. A rising trend is noticed.
ii. Defects Missed per Project over time
However, there is no noticeable trend in the bar chart below; the company is
not getting better in detecting defects. The goal is to see a downward trend
over the period of a year. This is definitely a watch list for to company.
iii. Acquired projects over time
The ultimate measure of a company’s growth can be the number of customers
and/or projects it acquires over a defined period of time. Using 11 years as a

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measure, the company hasn’t recorded any upward growth in the number of
projects it has acquired.

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CHAPTER 4
RESULTS AND DISCUSSION
4.1 TQM (TOTAL QUALITY MANAGEMENT)
TQM Cycle
We have developed a quality measurement system using the TQM method which is widely
recognized and has been used by several companies around the world. It is a cycle for
continuous improvement. The cycle begins with the Data collection stage during which the
company makes use of the spreadsheet that we have designed. After this comes the Data
analysis which is done using several statistical tools such as Mean, Range and Standard
deviation. The next stage is the corrective measures stage during which the company
implements changes based on the results gathered from the analysis. Finally, the company
takes a look at the manufacturing process to see if the changes that were implemented have
yielded good results and the cycle repeats itself.
Data collection
Data analysis
Corrective
Measures
Implemented
Check TQM MODEL

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Procedure for the FMEA Analysis
1.) Form a team of people with a wide variety of knowledge about the process, product or
service and customer needs according to the Process Step that is being analyzed.
These functions included are:
- Design
- Manufacturing
- Maintenance
- Purchasing
- Marketing
- Customer service
2) Identify the scope of the FMEA (Concept, System, Design, Process or Service )
3) Fill in the Failure Modes Analysis Effect (FMEA) form.
4) Identify the functions of the scope. For instance, questions like " What is the purpose of
this system, design, process or Service? What are the expectations of our customers? "
5.) For each function, identify all the ways failure could happen. These are all potential
failure modes.
6.) For each failure mode, find out the effects of the failure mode if it is not prevented.
7.) Rate how serious each effect is by giving it a rating. Severity, S is rated on a scale from 1
to 10 where 1 being insignificant and 10 most severe.
8) For each failure mode, determine all the potential root causes.
9) For each cause, determine the Occurrence rating, O. This rating estimates the probability
of failure occurring for that reason during the lifetime of the scope. Occurrence is rated on a

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scale from 1 to 10 where 1 is extremely unlikely and 10 is inevitable.
10.) For each cause, identify the current process controls. These may be test, mechanisms,
procedures and so on that you now have in place to keep such failures from reaching the
customer beforehand. These controls might detect the failure and prevent the cause from
happening.
11.) For each process controls, determine the Detection rating , D. This rating estimates how
well the controls can detect either the caus or its failure mode after they have occur but before
the customer is affected. Detection is rated on a scale from 1 to 10, where 1 means the control
is absolutely certain to detect the problem and 10 means the control is most absolute not to
detect the problem.
12.) Calculate the Risk Priority Number ( RPM ) which equals S x O x D.

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CHAPTER 5
CONCLUSION AND RECOMMENDATION
5.1 Conclusions
During our several visits to Tuck sin Engineering, we noticed a lack of statistical data to track
the growth of the company while also increasing the quality of the manufacturing process.
The design of this Quality Control System eliminates the dependence on the trial by error
approach, which is currently in use at TSG. Using our system, we are able to analyze the
performance level of the company in several key areas in order to enhance the productivity of
the company.
Our design still has several areas where it can be improved. It can be modified to measure
and analyze a much wider range of data thus further improving the quality and productivity
of the company. There are several software currently available in the market, which provide a
means of onsite data collection and analysis for manufacturing companies, but these software
come at a very high cost. The advantage our design has over such software is that it comes at
a very low cost and requires just a basic knowledge of statistical data analysis.
5.2 Recommendation/Next Steps
The design can be further improved to measure more areas of the manufacturing process.
In the current setup at TSG, they carry out work on Design, Fabrication, Detailing and
Erection services. Currently, our design only concentrates on design and fabrication.

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REFERENCES
1) http://www.tatasteelconstruction.com/en/reference/teaching-
resources/architectural-teaching-resource/technology/fabrication-and-erection-of-
steelwork/inspection-and-quality-control
2) https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja
&uact=8&ved=0CCIQFjABahUKEwiwr_nRxurIAhUDkJQKHe7RDw8&url=http
%3A%2F%2Fwww.tl9000.org%2Fregistration%2Fdocuments%2FDesign_Proces
s_Measurement_System_Guidance_Rev_2_1.pdf&usg=AFQjCNGyc3HFuHSip0
0qmuhdUSaiOhC5kQ&sig2=Gl8DG-
3) https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja
&uact=8&ved=0CCsQFjABahUKEwi2_Kn6xurIAhWBk5QKHfGaBcM&url=htt
p%3A%2F%2Fcife.stanford.edu%2Fsites%2Fdefault%2Ffiles%2FWP124.pdf&u
sg=AFQjCNHm22Xvyw6T__F-
EWqSzTKUDgkOUg&sig2=GLprhHSpaRRNtyEP4hrEMA&bvm=bv.106379543
,d.dGo
4) http://www.isixsigma.com/tools-templates/fmea/quick-guide-failure-mode-and-
effects-analysis/
5) http://asq.org/learn-about-quality/process-analysis-tools/overview/fmea.html
6) http://www.npd-solutions.com/fmea.html
7) http://webdb.ucs.ed.ac.uk/operations/honsqm/articles/fmea.pdf
8) http://www.geocities.jp/takaro_u/fmea_eng.html

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