This document discusses quality control, quality assurance, and quality improvement concepts. It provides examples of quality control and quality assurance activities in manufacturing, such as inspections, audits, and process documentation. Quality control focuses on inspection and testing to find defects, while quality assurance aims to prevent defects by improving processes. Quality improvement is about continuously studying processes to identify and implement solutions to problems. The goal is to create systems that prevent errors from occurring.

1. Growing a diversified
global business

2. Contents
Quality Assurance Activities
Quality Control Activities
Quality – an overview
Quality Control – Goal/Implementation
Quality Assurance – Goal/Implementation
Quality Improvement – Concept

3. Learning Objectives
 Quality Control
– Concept & Implementation
 Quality Assurance
– Concept & Implementation
 Quality Improvement - Concept

4. QA&QC Activities in Manufacturing
Quality Assurance
 Implementation of QMS.
 Control, update and revision of QMS documents .
 Conduct internal Audit and coordinates with ISO certified body for
certification.
 Coordinate with client for external / third party audits
 Maintain and control the Manual and SOP/MS/Written Practices.
 Control and monitoring of NCR’s / CARs.
 Second party audit of vendors and subcontractors.

5. QA&QC Activities in Manufacturing
Quality Assurance
 Preparation of documentation and Quality related procedures
 Conducts Quality Review Meeting.
 Review and analyze customer complaints and other re-occurring problems
in the process.

6. QA&QC Activities in Manufacturing
Quality Control
 To carry out stage and final Inspections & preparation of associated
reports.
 Client and Customer cordination and handling.
 Material inspection during receiving and before issuance to fabrication.
 Welding control and monitoring of repair rates
 Supervision of non-destructive testing.

7. QA&QC Activities in Manufacturing
Inspections
 Incoming goods inspection.
 Marking & layout inspection.
 Fit up inspection .
 Weld visual inspection.
 NDT Review ,Witness & Clearance.
 Hydro test witness
 Surface preparation & painting inspection
 Packing & Shipment inspection

8. QA&QC - Improvement areas
Concepts????
 Thinking that Quality is expensive; it lowers productivity
 Thinking that Quality is intangible; it cannot be managed
 Thinking that Poor quality means poor workers
 Thinking that Quality is the responsibility of quality department only
 Thinking that Quality is a Department
 Thinking that Quality is role specific
 Thinking that Quality is someone else’s job
 Thinking that Quality is not a major issue; it has little impact on the
company

9. QA&QC - Improvement areas
Where should we go from here?
We must go back to the past………. Back to the basics
Basics …………..
Which Quality leaders have been advocating from many years

10. Overview

11. Overview

12. Overview
NDE
Spool Erection Welding visual
& Welding inspection
Pressure
Testing Bevel, Fit-up,
Alignment etc
DESCON

13. Quality Control
Concept
 Process of making sure that products or services are made to consistently high
standards
 It is product oriented
 It coordinates the links between the following activities:
 Specifications of what is required.
 Components, elements of the product
 Inspection of the product to determine conformance to customer specification.

14. Quality Control

15. Quality Control

16. Quality Control
Traditional QC
Problems:
 Not a value-added activity
Too late
Costly
Human factor in inspections
Inspection of products and services
takes place during and at the end of
the manufacturing process

17. Quality Control
Example – Pressure Vessel Production
Raw material Final Product
 Quality Control, only, is not enough
 Inspections for defects – too late

18. Quality Control

19. Quality Assurance
Concept
 A set of activities designed to ensure that the development and maintenance
process is adequate to ensure a system will meet its objectives.
 A process of verifying or determining whether products or services meet or
exceed customer expectations.
 A process driven approach with specific steps to help define and attain goals.
 Quality assurance defines the quality policy and in turn, how to follow the
policies in better way to avoid any issues/defects thus saving time effort and
money in the production of product but also providing the customer with
exactly what they require.

20. Quality Assurance
 HOW SURE ARE YOU??”
:: focus on the process involves, and make sure you do the right thing.
 To ensure that the products/services meet the customer’s requirements at the
highest standard.
:: customer requirement/needs may change in time.
 Determine if the steps/process implemented to produce the product/service are
appropriate with the time and conditions.

21. Quality Assurance
 Internal audit / First party audit
:: a systematic, independent and documented
process, conducted by members within the
organization and obtain evidence and
evaluate it to determine where
requirements are fulfilled.
 External audit / Second or Third party audit
:: similar to internal audit, but conducted by
members not within the organization.

22. Quality Assurance
:: PDCA analyzes existing conditions and methods used to provide the
product or service to customer.

23. QC vs QA
 Quality control emphasizes testing and blocking the release of defective
products,
 Quality assurance is about improving and stabilizing associated processes to
avoid or at least minimize issues that led to the defects in the first place.
 However, QA does not necessarily eliminate the need for QC: some product
parameters are so critical that testing is still necessary just in case QA fails

24. Quality in an Organization

25. Overview

26. Quality Improvement
 Keyword : IMPROVEMENT
 The continuous study and improvement of a process, system, or organization
 A continuous process that identifies problems, examines solutions to those
problems, and regularly monitors the solution implemented for improvement.
 Example in manufacturing / industry : reduce product failures or work related
injuries.
 Example in administration / service : increase efficiency or reducing re-work.

27. Quality Improvement
 It is aimed at improvement - measuring where you are, and figuring out ways
to make things better. It specifically attempts to create systems to prevent
errors from happening.
 QI activities can be very helpful in improving how things work. Trying to find
where the “defect” in the system is, and figuring out new ways to do things can
be challenging and fun. It’s a great opportunity to “think outside the box.”

28. Quality Improvement
 Five (05) crucial activities to Quality Improvement

29. Quality Improvement
 An example: FADEE Model

30. Quality Improvement
Ordinary Company QI* Company
Quality is expensive. Quality leads to lower costs.
Inspection is too late. Workers should
Inspection is the key to quality.
produce defect-free goods, right at first time
Defects are caused by workers. Most defects are caused by the system
Rewarding the best performers and
Most variation is caused by the systems that
punishing the worst will lead to
judge, punish, destroy teamwork.
greater productivity and creativity
Profits are made by keeping
Profits are generated by loyal customers.
revenue high and costs down.

31. Quality Improvement

32. Quality Improvement
How can you make the difference?
 Be a quality professional – Who is quality professional?
 Starting point for improvement - recognize the need
 Be an agent for change in your organization
 Show people how to prevent problems, not just identify them
 Promote quality’s image - Inside & outside
 Constantly learn more about quality
 Educate, train, and support those who do the work