The term quality means different things to different people. Quality as conformance to specification. The 7 Quality Tools.
(I)
Customer-based quality: - Fitness for use meeting customer expectations.
(ii)
Manufacturing quality: - Conforming to design specifications or requirements
having no defects.
(iii)
Product quality: - The product has something those other Similar products do not
that adds value.
(iv) Value-Based quality: - The products are the best combination of price and feature.
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7 Quality ToolsÂ
The 7 QC tools are simple statistical tools used for problem-solving.Â
(i) Qc tools
(ii) Continuous improvement
(iii) Manufacturing
process
(iv) Quality
Control
(v) Root cause
analysis
(vi) PDCA (Plan
do check act.)
(vii) Efficiency
Methodology
for solving quality problems following seven QC tools are required.
Pareto
Diagram
Coast
effect diagram
Histogram
Control
chart
Scatter
diagram
Graphs
Six Sigma
Quality
Use Quality sort names or terms
FIFO =
first in first out
JIT = Just
in time
PCRO =
Public community regulatory organization
LQC = Line
quality control
CAPA =
Corrective and privative analysis
QIR =
Quality incident report
TPM = Total productive maintenance
BSR =
Bonded storeroom
TS = Total
Solids
TSS = Total
suspends solid
TDS = Total dissolved solids
TVS = Total
volatile solid
TFS = Total
fixed solids
INCOMING QA / QC
PROCESS DESCRIPTION of incoming QC:
After
receipt of intimation about the receipt of raw materials and packing materials from
stores through Material Receipt
cum Inspection Report (MRIR),
the samples are drawn as under:
a). A
composite sample adequate for testing from each lot of raw materials i.e. one
sample from different batch no’s & a composite sample from 25% containers from
each lot.            Â
b). 5 pcs.
of packing materials from each variety & each lot.
Inspection
of the materials is carried out as per documented standards for raw materials
& Packing materials & method of tests of raw materials. The records of
raw materials & packing materials testing are kept in the Raw Materials
Test Report and Packing Material Inspection Report respectively. In case GCS is written on the MRIR sample is not tested
but only preserved for at least three months and first supplies from such
suppliers are tested as per plan in each quarter.
In the case of
new raw materials, tests are carried out and their acceptance /rejections are
marked on the Supplier Selection Form Raw material rejection report is attached
for rejected materials.
Conformity
or non-conformity of material is recorded in the MRIR. In the case of accepted
material, the MRIR is sent directly to stores. In case of non-conforming
material, the MRIR is sent to V.P. / Head (O) who shall evaluate the material
and may authorize acceptance of material under deviation in case it does not
affect the quality of a final product.
Laboratory
reagents are prepared as per documented instruction and are kept well-identified and their shelf life is maintained as per documented instruction.
PROCESS OUTPUTS:Â
a)Â Decision to accept/reject incoming materials to stores.
b) Supplier selection forms to the purchasing
department with remarks.
IN-PROCESS AND FINAL QA / QC
PROCESS DESCRIPTION:
In-Process Inspection & Testing
After
receipt of intimation from production, the samples of intermediate &
finished goods are drawn and tested as per documented standards and
instructions for methods of test. In the case of lacquers, dyes & pigment
solutions & acrylic binders the Application Test is carried out and records
of chemical & application inspections are kept in
the respective batch sheets & F.G. Application Test Report respectively, and
results are conveyed to the production process. Â
Samples of all the batches of finished goods are preserved duly identified for at least 8 months for domestic and one year for export for reference. Old counter samples are renewed within one month and disposed of through re-cycling in production. Samples of the finished batch of each product as control samples are preserved for test comparisons. These samples are replaced with fresh lots after every six months.Â
If in 5 months no fresh batch is made, a lab batch is taken &
after its approval for all Q.C. tests, the same is kept as the control sample. For
Matt Lacquer & Filler, the control sample is replaced after 3 months. For
discontinued products, samples may not be kept. The records are maintained in
the Control Register (F-Q070-03). If the product is discontinued then the counter
sample is disposed of as hazardous waste to TSDF or used in a similar natural
product after getting approved from HOD (R & D).
PROCESS OUTPUTS: a) In-process test results to
production.
                b)
Decision to pass/fail finished materials to production.
ACTIVITIES QC & QA
TESTING OF
REGULAR RAW MATERIALS (RM), INTERMEDIATES, FINISH GOODS (FG), DYES &
PIGMENTS.
 TESTING OF NEW RAW MATERIALS, PACKING
MATERIALS, & TRADING MATERIALS (SYNTAX, FAT LIQUOR).
 INTRODUCE NEW TESTINGS IN DAY-TO-DAY ACTIVITY
TO STRENGTHEN OUR QUALITY SYSTEM, SUCH AS POT LIFE, GEL POINT, ASH CONTENT,
TANNIN %AGE & HYDROXYL VALUE.
COUNTER
SAMPLE PRESERVATION OF ALL FG, RM, DYES & PIGMENT.
HANDLING
OF CUSTOMER COMPLAINTS.
CALIBRATION
OF LABORATORY AND PLANT EQUIPMENT.
OPERATION
OF STP & ETP PLANTS.
QA
IMS
DOCUMENTATION, DISTRIBUTION, MONITORING,
AUDITS
& MR OFFICE ACTIVITY.
ALL LEGAL
COMPLIANCE MONITORING SUCH AS POLLUTION, LICENCE FOR NARCOTICS RAW MATERIAL ETC.
ISSUING ALL
THE REQUESTS OF CERTIFICATES LIKE REACH, RSL, VOC, LITERATURES, MSDS &
COA’S.
 CORRECTION, DISTRIBUTION, COLLECTION &
PRESERVATION OF BMR & PREPARATION AND CORRECTION OF SOPS ALSO.
APPLICATION
APPLICATION
TESTING OF ALL RM & FG.
GENERATING APPLICATION REPORTS & MONITORING ALL ACTIVITIES.