This document summarizes a study on the application of manufacturing standards in Pakistani public sector organizations. The study found that organizations with technology transfers and sector-specific standards applied had better quality products compared to those without. Training, availability and use of standards, acceptance/rejection rates, calibration systems, and management feedback were assessed. Organizations with calibration programs and those emphasizing feedback on defects had fewer quality issues. The study aims to show standards can improve Pakistani industry competitiveness and support sustainable growth.

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Asif Iqbal Butt, & Imran Saleem
Advanced Computing and Engineering Solutions,
Islamabad, PAKISTAN
piqc.com.pk

2. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 2
STANDARDIZATION IN STATE ENTERPRISE FOR
SUSTAINABLE GROWTH IN MANUFACTURING
SECTOR
AUTHORS Asif Iqbal Butt, & Imran Saleem
Advanced Computing and Engineering Solutions,
Islamabad, PAKISTAN
ABSTRACT The importance of manufacturing standards in quality assurance system cannot
be over emphasized. The standards help to establish a bench mark for
marketable products in a highly competitive manufacturing sector. The
requirements of modern technology are simple and clear for reduced product life
cycle. The changing customer expectations, globalization and financial openness
create cutting edge for countries and systems that believe in quality
consciousness and standardization. The sector specific standards help to acquire
technologies and R&D that creates take off points for growing industries.
The introduction of standards in manufacturing sector will bring standardization
in product(s) and improve quality acceptance criteria improving the credibility of
exports.
Keywords: Competitiveness, standardization, globalization, sustainable
growth, quality acceptance criteria.
INTRODUCTION Standards in any industry or country govern fundamental acceptance level of the
products or services. A standard is defined as the level of quality or excellence
that is accepted as the norm by which actual attainments are judged. American
society of testing and materials (ASTM) provides a platform for consumers,
suppliers, Government and academia to perform acceptance testing to asses
whether American products and services meet acceptable industry standards. The
ASTM standard is defined as set of rules that has been established with the
consensus principle of society and that meets the approval requirements of ASTM
procedures and regulation. The cycle of working of a discrete product and
description of the scope of standards, Khan (2006) for engineering design and
manufacturing is shown in fig 1.

3. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 3
Input Energy /
Work Forms
Structure/ Mechanism/ Machine
Static Dynamic assembly
Static Dynamic Components
Objective function
Output Energy /
work forms
Convenience
Pleasure
Better living
standard
Waste
1. Liquid of Varying PH
2. Gases of Various composition
3. Solid/ Powder from used fuel
4. Solids from used/ discarded
components/ structure/ assemblies/
mechanisms/ machines
A complete cycle of the working of discrete product
Standard for Permissible Range
Standard governing Thermodynamic or Fluid
Processes
Standard for Static and Dynamic Components i.e. Gears,
Bearing, Fastener, Standard Components
Standard for Assemblies (Mechanism and Structures) e.g.
Chassis of an Automobile , Wing of aero plane
Standard for Machine e.g. Pick and Place Robots, CNC machine tools, Material Handling
Standard for Design Methodology, Analysis Techniques
Environment related Standards
Quality Assurance Standard
A general description of scope of standards for engineering design and manufacturing
The working cycle explains the requirements of input energy such as thermal,
hydraulic or electrochemical reaction to drive the machines to give output energy
or work form. These actions which have an objective function result into waste
such as gases or solids. The structure, mechanisms and machines contributing to
a discrete product have static or dynamic components which are assembled
together to give us the required structure, mechanism and machines. The
description of standards signifies the need for acceptance criteria for product as
a whole, during the process, assembly, manufacturing and Quality Assurance.
Other developing countries have applied standards where required. This
accentuates the fact that application of required standards through systematic
evaluation and verification benefits all producers.
NEED FOR
STANDARDS IN
The Importance of manufacturing standards in quality assurance system cannot
be over emphasized. Standards help to establish a bench mark for marketable
products in a highly competitive manufacturing sector. The introduction of
Figure 1:
Figure 2: A general description of scope of standards for engineering design and
manufacturing

4. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 4
DEVELOPMENT
OF
MANUFACTURIN
G INDUSTRY
standards in any manufacturing sector brings standardization in product(s) and
improves quality acceptance criteria, enhancing credibility of exports. The
problem identified for the manufacturing sector in any country is lack of sector
specific standards which are necessary to provide a basis for growth.
BENEFITS OF
THE
STANDARDIZATI
ON
DIN (German Institute for Standards) in a case study DIN (2000) has analyzed the
benefits of standardization on businesses, standard bodies, economy and state.
The study indicates the general ignorance of German industry about standards
and consequent advantages in cost, competitiveness, product safety and R&D
cost savings. The study further highlighted the benefit of technology changes,
innovativeness, foreign trade, exports and trade barriers on the economy.
The analysis from the research is presented here: -
Improvement in the quality of products
There are positive effects of company wide standards for competitiveness as
compared to industry wise standards. A greater competition for quality and
reliability exists as standards avoid dependence on a particular supplier.
Quality of services, health, safety and environment
International standards help to achieve greater competitiveness and technology
transfer from advanced nations through transparent technical specifications and
removal of old standards.
Efficiency Resources
Based on the concept that technical rules are turned into specified standards,
the companies already in process of adopting standard avoid cost of conforming a
standard introduced at later stage. It is experienced that standards are not a
hurdle to innovation / R&D and Company wide standards are profitable for firms
having common goal than following industry wide standards.
Trade enhancement
Harmonization of European & international standards results in lower trading
costs and large number of standards in a particular sector results in export
surplus. Further more identical international standards result in simplification of
contracts and lowering of trade barrier.
STANDARDS AND
INDUSTRIAL
COMPETITIVENE
SS
Existing research is based on the adoption of sector specific standards by
technologically advanced nations and innovative countries. These efforts by
technologically advanced countries to maintain their competitive edge through
standardization and diversification of products is advocated by quality Gurus like
Deming, Juran and Ishikawa, who contend that development of high quality
products is possible only through R&D. In other words improved materials and
process technologies innovation and highly skilled manpower can only be
developed through knowledge of sector specific standards and efforts undertaken
to attain these standards.
Research is being conducted on an increasing number of processes, features etc
of conventional and non-conventional production. Even negative processes of
production which are thought to be irreversible can benefit from the application
of standards. Hoar (1976) has quantified the cost of corrosion in the absence of
any acceptable standard for corrosion control. Historically, for plants and
product life cycles allowances for corrosion losses is taken in to account,
however this study yields optimistic results with regards to the estimates of
saved cost on account of corrosion control. He estimated that a savings of 310

5. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 5
Million pounds compare to their investment of 1365 Million pounds for industries
like Engineering, oil ,power and transport. His findings are valid for all industries
which use metallic and nonmetallic coatings will incur similar corrosion costs.
STANDARDS AND
THEIR NEED FOR
INDUSTRY
This research investigated the availability of manufacturing standards in
organizations, how they can be applied in setting quality standards and reducing
costs. This Study targets Public and private enterprise involved in manufacturing
of various products and dependence on sound rationale for quality assurance
program in products and process design. The interface of technology and
availability of relevant standards demonstrate potential strength of the
manufacturing sector to be competitive in post WTO environment. It is envisaged
that these sector specific standards will create good competitive grounds for our
Oil & Gas, IT, manufacturing and textile sector. Standardization will improve
productivity in agricultural sector which is seriously hampered by absence of
quality standards for machinery, yield, irrigation and fertilizers.
This research involved analyzing production processes and subjecting these
processes to detailed analysis and evaluation for availability of standards. This
compared Special welding processes based on Gas Tungsten Arc welding (GTAW)
and Plasma Welding for American welding society standards and American
National Standard Institute (ANSI). A case study from a local industry is presented
here to have a comparative model for the subsequent research.
CASE STUDY A study for welding through GTAW and Plasma techniques in a Boiler
Manufacturing unit for low alloy steel was carried out. The study initially used
TIG technique for welding and then switched over to plasma technique for
welding of the boiler parts to under stand the phenomenon and possible effects
of mix mode welding. ASTM A 577 describes the method for straight beam ultra
sonic examination for steel plates. The standard was applied for the acceptance
of steel plates. After rolling of steel sheets a standard for straightness by
American national standard institute standard( ANSI no H35.2 having allowable
tolerance deviation of 0.3 mm for length more than 12.5 mm was followed.
Table 1: The welding Parameters for Plasma and TIG
COMPARISON
Parameters GTAW PLASMA
Weld passes 4 1 or 2
Current Range 180 Amp 155 Amp
Wire Speed 17 cm/min 65 cm/min
Carriage Speed 20 cm/min 25 cm/min
Operating Temp
Deformation
HAZ
2800~3200 C
High
Large
3000~3500 C
Low
Less
TIG (electric arc welding) SAF Training Manual (2002) uses a refractory electrode
with a gaseous atmosphere. The inert gas (Argon / Helium) isolates the melting
metal, hot zones and Tungsten electrode from the air. The heat given by the arc
causes the part and the filler metal to melt and a bead is formed. The weld has
good quality and compactness.
The Plasma works on the concept that in the natural state, a gas is a neutral
electric insulator. The atoms of gas are in rapid motion and this is increased
when the movement of gas is increased. The number of electrons leaving the
atoms also increase the atoms breaking loose are said to be ionized. With
accelerated movement, this causes increase in temperature to go up to several
thousand degrees. This ionized gaseous body is conductor of electricity and
called Plasma. When Plasma is used in welding the arc reaches 25000 degrees K
through concentration of energy transmitted to the part. This is due to the
mechanical arrangement and constriction of the electric arc in gaseous

6. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 6
atmosphere.
The requirement of heat treatment is dealt through Table A, 1.2 ASTM A 480/A
Requirements for heat treatment which signified heat treatment temperature of
1040 degrees centigrade and quenching in water or through other means. The
data for qualification of Boiler sheets is presented here which will demonstrate a
higher rate of non conformance in product acceptance and subsequent repairs
involving high cost of quality.
0
10
20
30
40
50
60
70
80
90
Number
Presented
cylinders Flanges Dish 1 Dish 2
Part Description
Quality Acceptance-Parts
Total
Passed
Repair-1
Repair- 2
Reject
The values for allowable deviation from specified diameter is important in line
with Table A 2.10 of ASTM A 480 which stipulates Permissible allowance of 6 mm
over a diameter from 600~1200 mm. A data was taken to measure allowable
deviation from specified diameter in pressure vessels welded through GTAW and
Plasma techniques. Although variations are not pronounced but significant
difference is observed in the values for allowable deviation. The values are
recorded in mm.
ANALYSIS The case study analyzed the causes of non-conformances in the developmental
stages. The rework due to defective welding was present in two out of eight
sheets in case of GTAW welding and four out of eight sheets in case of plasma
welding. From the study conducted, it is concluded that changes in welding
process from GTAW to plasma warranted a change in process parameters like
current, speed and use of electrodes. These parameters were adopted; however,
instead of a straight edge preparation a V notch preparation was followed. This
resulted in multiple passes required for the GTAW being applied for Plasma
welds. Increased number of passes resulted in deformation in plates and radio
graphic defects leading to excessive repairs. A study is currently undertaken to
highlight the effect of special heat treatment cycle required for Plasma welding
to minimize distortion and qualify all required mechanical properties as per
standard.
Quantitative analysis of single and multiple repairs has been identified through
cost estimation. The data is shown in the table and highlighted as cost of Quality
in case of rework / Process finalization.
Figure 4: Quality Acceptance of Boiler and parts
Side
End-1
Side
End-2

7. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 7
0
5
10
15
20
25
30
35
40
45
50
Cost in
Thousands
Cylinder Dish-2
Product Description
Cost of Repairs
First
Second
Figure 8: Costs of Repairs in Rupees for Boiler plates and parts
0
10
20
30
40
50
60
Cost(000)
Prevent Appraisal Internal External
Cost Breakdown
Quality Matrix
Training
Normal
R-1
R-2
Delay
Returns
Recall
Figure 9: Quality Matrix and Cost breakdown in Rupees for various heads
Based on the case study as a bench mark for our research, application o
manufacturing standards was analyzed in public sector organization such as
Railways, ACES Engineering, HMC and ACP. Some of the results/salient of the
study analysis are presented here. The results of variables are shown in
consolidated form at the end.
Training
Training dealt awareness about standards in Organizations, level of training
imparted, special techniques and documentation. Training was graded higher in
case of organization having transfer of technology (TOT) and more importantly as
process requirement. It was low in other public sector organizations having no or
Side
End-1
Side
End-2
(In thousand)

8. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 8
little TOT. Pakistan Railways provide good training to raw welders in special
technologies such as CO2 welding. However they are unable to retain qualified
welders due to less pay and incentives, however had auto dated standards and
documents?
Availability of Standards
Issues such as availability of inspection standards, special techniques, acceptance
criteria’s, process documentation, technology and drawings were analyzed Public
sector organizations did fairly well on the availability of relevant standards and
pertinent documents.
Application of Standards
Application of welding parameters, use of inspection instruments, environmental
conditions and acceptance of welding materials prior to use were focus of
research. Significantly, organization with some form of TOT have inbuilt
mechanism to follow standards. Sampled firms with little or no TOT demonstrate
less application of standards.
Acceptance/Rejection
Respondents were inquired about recording of data, minimizing welding
problems, customer feedback and steps taken to improve quality after analysis of
reject products. The quality of products was gauged fairly satisfactory in case of
sampled organizations. Importantly, firms having adopted sector specific
standards in tangible form demonstrated improved results as compared to other
organizations.
Calibration
Calibration and verification of instruments used in welding process. The
comparison of performance was based on the sampled firms having some form of
calibration activity for special instruments. It is concluded that a wide gap in
quality of product exists between organizations having well placed calibration
system as compared to those having none system. The quality of the product is
affected due to non-calibrated instruments that result in inferior products.
Feedback
Data for non-conformances, complaints from user and monitoring by top
management were analyzed. Feedback on welding merits a sound approach to
minimize quality related failures and improved products. Feedback was very good
in one sampled organization and satisfactory in all others. It can be inferred that
importance of feedback is lacking in most cases. Consequently steps taken to
minimize such bottlenecks through frequent analysis by management will
improve quality of the product.
Figure 9 Application of Standards against selected Variables
Application of Manufacturing Standards in Industry
64.4
51.1
84
91.1
80
74
88.9
96
92
51.1
72
68
55.6
80
64
53.3
64
70
0
20
40
60
80
100
120
Variables
MeasurementofVariables
A 64.4 51.1 84
B 91.1 80 74
C 88.9 96 92
D 51.1 72 68
E 55.6 80 64
F 53.3 64 70
Training Standard Application Standard Availability

9. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 9
Figure 9: Application of Standards against selected Variables
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Royal Society of London Vol 348, No 1652 Feb 1976, 1-18
2. Farooq (2006, March 28) “Improving Quality Infrastructure / trade under
WTO” The News P.4.
3. Lois Stanford (2002), Constructing Quality, The political economy of
standards in Maxico avocado industry.
4. Verschuren P (2005) Evaluation in Design oriented Research, Quality and
Quantity (2005) 39: p 733-762
5. Shahid Burki, (2006) The News 28 March 2006, The Future of Pakistan
Economy
6. Ali Sajid (1995) Role and Performance of Public Manufacturing Enterprise
in Developing Countries. A Case Study of Pakistan 1972~89. Phd, The
George Washington University.
7. Lee C.S, Kin J.S, Choi C (1998) Research process of Advanced Titanium
Alloys in Korea” Advance Performance Materials 5, p. 331-339 (1998).
8. Jean Pierre, Monchalin (1998) “Laser Ultra sonics from the laboratory to
the shop floor” Advance Performance Materials 5, p 7-23 (1998).
9. Farzin Y.Z. (2003) “The effects of emission standards on the industry”
Journal of regulatory economics: 243, p 315-327, 2003.
10. Khan, Wasim A, (2006) Standards for Engineering Design and
Manufacturing Taylor and Francis, pp. 66-73.
11. ASTM (1998) Annual Book of ASTM standards “Iron and steel products “Vol
01.03, pp 344.
12. SAF Manuals on training for Plasma and TIG welding (2002), Issue N-0 No
Application of Manufacturing Standards in Industry
64.4
51.1
84
91.1
80
74
88.9
96
92
51.1
72
68
55.6
80
64
53.3
64
70
0
20
40
60
80
100
120
Variables
MeasurementofVariables
A 64.4 51.1 84
B 91.1 80 74
C 88.9 96 92
D 51.1 72 68
E 55.6 80 64
F 53.3 64 70
Training Standard Application Standard Availability
Application of Manufacturing standards in industry
68.9
73.3
7071.1
80
75
84.4
100 100
66.7 66.7
60
64.4
46.7
70
66.7
73.3
65
0
20
40
60
80
100
120
Variables
MeasurementofVariables
A 68.9 73.3 70
B 71.1 80 75
C 84.4 100 100
D 66.7 66.7 60
E 64.4 46.7 70
F 66.7 73.3 65
Quality Accept/rejct Calibration Feedback & Control

10. Pakistan’s 10th
International Convention on Quality Improvement ICQI`2006
© Pakistan Institute of Quality Control 10
1515-9881
13. DIN German Institute for Standardization (2000) Economic Benefits of
Standardization, Summary of results. Dresdon and Karksruhe.