QUALITY OF INSPECTION SERVICE

What is inspection?

Inspections are?a formal process, cornerstone in the quality control, a collective team effort with respect to establishments and primary producer involve act of careful examination or scrutiny, verification. i.e., observing, understanding examining and assessing something to identify errors, correct errors or defects in a process deliverable.

Principles of inspection: -

Principle of inspection are same as quality system like

·????????Customer focus,

·????????Leadership means different quality control rules to detect different analytical error

·????????Process approach.

·????????Continual improvement

·????????Evidence-based decision making

·????????Relationship building between customer & supplier with premium class verification.

Purpose/ objectives of inspection: -

Main objective of inspection is?

·????????To meet customer requirements, wants, and needs.

·????????To prevent defective product flowing down the successive operations

·????????To prevent loss to the company.

·????????Listen to the concerns of workers and supervisors

·????????Understanding of jobs and tasks

·????????Identify & determine existing & potential hazards, loop holes and its causes

·????????Recommend corrective actions

·????????Monitor step to eliminate error, risks & hazards

Types of inspection: -

Generally, while we think of inspection it come to our mind about pre shipment inspection but if we carefully analyse, we found there are different phase of inspection to be maintained for keeping a consistent quality output

·????????Design & Development stage

o??Pre-approval inspection.

o??Routine inspection.

o??Compliance follow-up inspection.

o??“for cause” inspection.

o??Regulatory Compliance Inspections.

o??Sample Checking.

·????????Production stage

o??Pre-Production Inspections (PPI).

o??During Production Inspection (DPI).

o??Pre-Shipment Inspection (PSI)/ final random inspection.

o??Piece by Piece Inspection (or Sorting Inspection).

·????????Loading and unloading supervision

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But it is to be remember that general testing?is not the method for inspection for defects.

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Benefits of quality Inspection: -

Overall benefits: -

·????????Satisfied & comfort customers

·????????Reduce errors & increase accuracy

·????????Real time data collection for analysis

·????????Save warranty cost, lower shipping cost, reworking manhour

·????????Increase morale

·????????Improved production methods

·????????It fosters a quality consciousness in employees

Benefits of first article inspection (Applicable for prototype): -

·????????Preventing miscommunication and solving problems

·????????Verify that your requirements/standards are understood

·????????Certainty in terms of the use of the right materials / designs / dimensions / colours, etc.

·????????Implement improvements for the mass production

·????????Prevent additional costs and delays

·????????Effective start for the expected result

Benefits of during production inspection (DPI): -

·????????Discovering and resolving complications in well advance time.

·????????Intervention to prevent delays

·????????Maintaining quality at the right level

·????????Preventing risks relating to costs and delays

Benefits of pre shipment & final random inspection (PSI): -

·????????Final window of quality assurance before reach to customer hand

·????????Make sure the quality of your goods is ok before final payment?

·????????Extensive inspection report for both internal and external use / support

·????????Overview of any shortcomings

·????????No surprises and uncertainty

·????????Shipment decisions can be taken basis of the report.

·????????Demonstrating to your supplier about great value & certainty on quality

Benefits of loading & unloading supervision: -

·????????Certainty that what is being loaded is what you ordered

·????????Accurate packaging and shipping marks

·????????Instruction for suitable care to prevent damage

·????????Ensure quantities are the same as those on the packing list.

·????????Verified quality of container, stuffing & experts sealing like fumigation etc.

·????????Certainty of quality transport

Operational procedure for inspections: -

1. Planning and scheduling for inspection
2. Overviewing & understanding products / service/ activity to inspect
3. Preparation for inspection with all input documents, checklist & guidelines of establishments to verify & identify defect
4. Implementation or execution of inspection with examine, scrutiny & verification, evidence collection
5. Inspection meeting joint meeting & agreement with supplier & possible compliance.
6. Documentation for record keeping
7. Rework as per compliance to makes changes to the work product according to the action plans from the inspection meeting.
8. Follow up the changes by the author are checked to make sure everything is correct

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Role of quality inspector: -

In my role as a quality assurer & expeditor I thought following activity an inspector clear with.

·????????Coordinator: - plans the inspection and coordinates it.

·????????Author:?The person who created the work product being inspected.

·????????Moderator:?This is the leader of the inspection. The moderator

·????????Observer & reader: - The person goes through the documents, one item at a time & observe the required details. The other inspectors then point out defects.

·????????Recorder/Scriber:?The person that documents the defects that are found during the inspection.

·????????Verifier & defect/ deviation finder:?The person that examines the work product to identify possible defects.

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Examination areas during inspection (Equipment, process, people, environment): -

·????????Authority, procedure, venue, method & competency

o???Who carry out inspection? How much inspector aware of the result criteria & legislative requirements?

o???What degree & details inspection have done? What machinery & instrument used to carry out inspection?

o???Where & which location inspection carried out?

o???When (shift/activity) & under which circumstances inspection carried out?

o???How frequent & which method is used to complete inspection? How much attention an inspector gives for high risk high hazardous area?

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·????????Impact of adverse environmental aspect & hazards of working climate

o???Stress

o???Wear

o???Impact

o???Corrosion

o???Chemical reaction?

o???Misuse.

o???Temperature

o???Noise

o???Vibration

o???Lighting

o???Ventilation

o???Electricity

o???Radiation

o???Pressure

·????????Functional consistency

o???Interlocking

o???Timing

o???Emergency & local control, remote control

o???Movement

o???Communication, feedback

·????????Equipment used includes

o???Materials

o???Tools

o???Apparatus for producing a product or a service.

·????????The process involves

o???How the worker interacts with the other elements in a series of tasks or operations.

o???Activity authenticity & uniformity

o???Standard follows

·????????Adequacy of operator safety considered

o???Machine, live terminal guards

o???Unsafe workplace conditions,

o???Unsafe work practices.

o???Spread of disease due to viruses, bacteria, fungi and parasites.

o???Ergonomics (physiological and psychological) related

§?Repetitive and forceful movements

§?Awkward postures arising from

§?Improper work methods,

§?Improperly designed workstations, tools, and equipment.

§?Chemical hazards caused by (Solid, liquid, vapour, gas, dust, fume or mist.)

§?Psychological status like (Overwork, stress, bullying or violence, motivation)

Documentation involves: -

Inspection is verifying or review of product, service, operation or organization based on establishments requirements its needs basic input documents

Input documents: -

·????????Legal contracts which make you permissible for carry inspection like contact, purchase orders.

·????????Specifications over which inspection will be carried out like

o???Final approved documents & drawing (manufacturer specification, arrangement, layout, SLD, scheme), data sheet material & chemical used, bill of materials etc.

o???National & international standards

o???Previous inspection/ investigation reports or minutes of meetings, recommendation.

o???Monitoring & maintenance report, compliance report

o???Organization specific policy & tolerance criteria

·????????Product/ service operation criteria & application area.

·????????Process flow chart, workforce size, shifts and supervisor name, Job procedure required.

·????????Inspection checklist or inspection criteria sheet of particular product or services.

·????????Approved quality assurance plan

·????????Internal test report & readiness evidence.

·????????Tolerance criteria, storage area

·????????Workplace rules & regulation, safe work practice guidelines, emergency procedure

·????????Inspection tool if anything like software & hardware etc.

In process documents: -

Basically, on observation & evidence collection

·????????Observation during inspection like

o???Sampling method

o???Object specific identification like serial no., Job sheet etc.

o???Testing procedure, testing result, calculation method

o???Quality assurance procedure maintained & product traceability accountability.

o???Instrument used, its calibration & traceability.

o???External origin products quality control method & document

o???Usage of PPE by operators & safety precaution adapted

o???Authorization of use of machinery

o???How defective tools are tracked

·????????Evidence collection

o???Routine test report

o???Measuring instrument calibration report

o???Bought out items test certificates.

o???Testing & calculation result collection

o???Relevant photograph.

o???Type test, safety related certificates for hazardous products like chemicals, gas, liquids etc

Inspection report/ output document: -

This inspection report can be categorised as per types of inspection for keeping records (DPI, PSI & final)

·????????Agreeable minutes of meeting about observation

·????????Change & as manufactured drawing

·????????Compliance of observation

·????????Certification of acceptance or clearance

·????????Tagging of clearance

Report should also include priority levels in observation with respect to objectives like

·????????Critical - requires immediate action

·????????Major - requires short-term action

·????????Minor - requires long-term action

Competencies of inspectors required: -

choices of personnel to carry out formal inspections

·????????knowledge of regulations and procedures

·????????knowledge of potential hazards

·????????Experience with work procedures involved

It can be engineers, maintenance personnel, occupational hygienists, health and safety professionals, supervisors or managers may be a part of the inspection team or they may be called upon to help with certain aspects of the inspection, or to help explain equipment or processes.

Some common poor work practices: -

·????????Unauthorised use of machinery or tools.

·????????Violation of safe work practices & method like standing or working under suspended loads, scaffolds, shafts, or open hatches

·????????Improper & ineffective usage of personal protective equipment.

·????????Using defective tools or equipment or using tools or equipment in unsafe ways.

·????????overloading, crowding, or failing to balance materials or handling materials in unsafe ways, including improper lifting

·????????Repairing or adjusting equipment that is in motion, under pressure, or electrically charged

·????????Creating unsafe, unsanitary, or unhealthy conditions by improper personal hygiene, by using compressed air for cleaning clothes, by poor housekeeping, or by smoking in unauthorized areas

·????????Discussion with or observation of workers who may be overloaded, fatigued, working in conflict with others, or working in isolation (working alone)

Follow up & Monitoring: -

Information review & analysis from regular inspections to identify where corrective action was needed.

Use older reports to identify trends. analysis of inspection reports leads to follow up & monitoring for ?

• Priorities for relevant corrective action
• Need for improving process and method of work practices
• Implementing control like improvement or development
• Understand, identify reason & isolate fault area
• Need for awareness, education and training

. In-depth hazard analysis

Digital/ Virtual/ On line/Remote inspection: -

A virtual inspection allows?a building inspector to remotely view the site using a webcam controlled by the property owner or contractor.

Done by use?an online cloud-based meeting tool in conjunction with your permitting software. like Zoom, GoToMeeting, Skype or even FaceTime to complete live walkthrough inspections without physically being at the property.

·????????Planning, checklist design, session scheduling & review same as manual inspection

·????????Preparation, during session, submission & documentation for virtual inspection are different like

·????????Good communications system like (Bluetooth, internet speed, video conferencing system)

·?? Evidence collection are different

Advantages: -

Cost saving due to travel manhours?

Disadvantages:?

Audio, video, communication media speed, surrounding environment & other hazard, complete inspection might not be encountered, misinformation, incomplete inspection & also inspection can be manipulated.

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