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What's the best way to choose quality control tools for different manufacturing processes?

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Quality control is a vital aspect of manufacturing operations, as it ensures that the products meet the specifications and standards of the customers and the industry. However, choosing the right quality control tools for different manufacturing processes can be challenging, as there are many factors to consider, such as the type, complexity, and variability of the process, the cost and availability of the tools, and the goals and objectives of the quality improvement program. In this article, we will discuss some of the best practices and tips for selecting quality control tools for different manufacturing processes, and how to apply them effectively and efficiently.

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1 Identify the process characteristics

The first step to choose quality control tools is to identify the characteristics of the manufacturing process, such as the input, output, and transformation stages, the flow and sequence of activities, the resources and materials involved, and the sources and types of variation and defects. By understanding the process characteristics, you can determine the appropriate level and scope of quality control, and the most relevant and useful tools to monitor, measure, and analyze the process performance and quality.

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Ben Shachar

Supply Chain Management
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I would add risk evaluation once the processes have been mapped out, this will be helpful during the time of resource allocations.

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Michael Lantz

Retired with Sandy
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Start by assembling all the critical design attributes starting with the specification. What exactly are we making this thing to do. Then develop quality checks to verify these. Remember that one “check” can address a number of attributes.

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Gabor Kertesz

Lean Manufacturing ? Operations Management ? Quality Assurance ? Team Development
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Scrutinizing the information/documentation entering and traveling through production is just as (if not more) important as it is to QC the actual product being processed. Ambiguous, vague, incomplete or incorrect information will doom the whole production process before it even starts. Documentation review QC checkpoints can minimize this risk, but these usually happen before the production process starts. Training all employees in the production process itself to signal when they suspect such errors in the information/documentation they receive ("stop the production line") will also help discovering human errors before they end up resulting in defective products.

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2 Select the quality control methods

The next step in the process is to select quality control methods that are suitable for the process characteristics and quality objectives. Quality control methods are systematic techniques used to guarantee that the process meets quality standards and requirements. Inspection, testing, sampling, and auditing are all common quality control methods. Inspection involves checking and verifying the quality of products or components at various stages of manufacturing, either manually or with tools such as gauges and sensors. Testing involves applying a stimulus or condition to products or components to assess their performance, functionality, reliability, or durability, in a laboratory or real-world environment. Sampling involves selecting a subset of products or components from a larger population to assess their quality and representativeness using sampling plans or software. Lastly, auditing involves reviewing and evaluating the quality system and activities of the manufacturing process with checklists or questionnaires.

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3 Choose the quality control tools

The final step is to select quality control tools that support and complement the quality control methods, while providing useful information and insights for quality improvement. Quality control tools are graphical or statistical techniques used to collect, display, analyze, and interpret data. Common tools include flowcharts, check sheets, Pareto charts, histograms, control charts, scatter diagrams, and cause-and-effect diagrams. Flowcharts visualize the steps and interactions of the manufacturing process to identify potential problems or bottlenecks. Check sheets record and organize data such as the frequency or location of defects. Pareto charts show the relative importance of different factors or categories of quality problems. Histograms show the shape and variation of data to assess normality or skewness. Control charts monitor and control stability and capability over time. Scatter diagrams show the relationship between two variables. Finally, cause-and-effect diagrams analyze root causes and sources of variation.

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4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ben Shachar

Supply Chain Management
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Set parameters to track performance, once results show outside the set parameters attention would be required by quality control.

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Manufacturing Operations

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What's the best way to choose quality control tools for different manufacturing processes?

1

2

3

4

1 Identify the process characteristics

2 Select the quality control methods

3 Choose the quality control tools

4 Here’s what else to consider

Manufacturing Operations

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What's the best way to choose quality control tools for different manufacturing processes?

1

2

3

4

1 Identify the process characteristics

2 Select the quality control methods

3 Choose the quality control tools

4 Here’s what else to consider

Manufacturing Operations

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