4 Steps of Quality Control

Quality control is a set of processes that companies use to ensure products and services are up to their standards. This helps companies improve their reputations, avoid faulty products, and increase customer trust.

Generally, quality control is part of a company’s quality assurance (QA) program. However, some companies implement QC methods in addition to their QA programs.

  1. Plan for Quality

Quality control is a crucial component of any project. It can ensure that you meet the expectations of your stakeholders and customers, reduce costs by preventing defects in production, improve efficiency, and build a positive reputation for your business.

You should begin your quality planning by determining the goals and standards that you want to achieve. This can help you create a more focused plan for your project that will keep everyone working towards the same goal.

Then, you need to consider how to measure your quality goals and prevent defects during the project. This can include testing the product, analyzing the test results, and figuring out how to correct any issues that arise during the process.

Once you have your quality goals and standards in place, you must ensure everyone involved with the project understands those requirements and can follow them effectively. This includes everyone from the project manager to the quality control manager and even members of the team.

For example, the quality control manager should ensure that all quality management standards are followed and highlight any deficiencies to the project manager. The project manager can then use these standards to determine if the quality goals are being met or if more work needs to be done.

Another important element of your quality planning is deciding the defect classifications, AQLs, and inspection levels you will use for the project. These will help you determine if the factory is meeting your quality standards and help you identify what steps you should take when issues arise.

You can use a variety of tools to perform quality inspections, including onsite tests, lab testing, and QA checks. You should also decide how often you want to use these tools.

Inspections done by a professional quality associate are essential for preventing defects from occurring in your products. They can prevent defective units from leaving the factory and detect problems early on that can be fixed before they become big issues. They can also help you track the status of your product and keep your quality goals in check, which can save you time and money.

  1. Perform Quality Inspections

Performing quality inspections is an essential part of any company’s manufacturing process. It helps ensure that products are produced according to company standards and customer requirements. It also prevents the reoccurrence of product failures and can cut production costs and efficiency.

The most common types of quality inspections include pre-production inspection (PPI), during-production inspection, and pre-shipment inspection. Each has its own purpose and can be used depending on the needs of your business and its supply chain.

PPIs help you assess the readiness of the factory and the quality of procured raw materials before the start of production. They also help you to identify and anticipate any issues in materials, management, or timelines before they occur. This step can be beneficial if you work with a new supplier, especially if your project is large and has critical delivery dates.

In-process quality control inspection is conducted by a third party to ensure that the first finished products from the line conform to specifications. It requires an expert technician to reliably detect errors on unfinished products, but it is a valuable step to take in production.

However, this type of inspection is often not carried out if there are significant changes in product quality over time or if testing intervals need to be established. It can be expensive to perform, and human error is a major issue when conducting this type of inspection.

This inspection can be used to confirm that the packaging meets all specifications and is compliant with regulations. It may also involve a visual examination of the packaging to look for any defects that could affect the safety and quality of the final product.

Once the production of a product is complete, it must be inspected to ensure that all components are in working order. This includes the product itself, the packaging, and any other components not included in the package.

The best way to perform this type of inspection is by creating a checklist and implementing it across your construction processes. This will ensure that all essential items are checked and a record of the inspection can be kept.

  1. Report Defects

When quality control inspectors find defects in a product, they must report them. This crucial step can prevent products from reaching their customers in unsafe conditions. It can also ensure the safety of consumers and reduce legal liabilities if products cause harm.

Traditionally, inspectors report quality issues by handwriting reports on paper or entering data into spreadsheets. These processes are time-consuming and often take their focus away from inspecting.

To avoid this, manufacturers need to implement a system that can track production issues in real-time and automate defect reporting. An automated system can help improve efficiency on the manufacturing floor, allowing operators to input their data into ruggedized tablets as they conduct inspections throughout the day.

This allows supervisors to quickly review and identify insights so they can issue corrective actions as needed. It can also help companies lower defect rates and secure their reputations by delivering consistently perfect products.

The key to successful defect reporting is ensuring that all information is captured accurately and properly. This includes details like the defect’s description, stack traces, expected and actual outcomes, and other vital information.

In addition, the report should be organized so that developers can quickly locate the defect when they need to fix it. This can include screenshots, video recordings, and the source URL so that they can see the exact location of the defect.

Defects that are not reported can be costly for manufacturers, resulting in lost sales and decreased brand loyalty. These problems can also lead to lawsuits and damage a company’s reputation in the long run.

As a result, most manufacturers are turning to new-age quality control processes that efficiently keep defects at bay while maintaining high levels of quality. In doing so, they can save money and boost the profitability of their business.

Whether you are a small or large company, the cost of defects can be significant. These issues can halt growth and impact your bottom line. This can be a huge financial burden on your company, so it’s important to invest in quality control and defect tracking systems that minimize these costs.

  1. Correct Defects

Managing product quality is one of the greatest challenges for importers. While minor defects often fly under the radar, relatively severe quality defects can lead to dissatisfied customers, product returns, legal repercussions, and even product recalls.

Fortunately, there are ways to prevent and correct defects before they become a significant issue for your business. Using an effective quality control checklist is one way to do this.

This checklist should include information about inspection levels, AQL tolerances, and any other special requirements that must be met to ensure the quality of your product. This will make it easier for your inspector to understand what needs to be done and reduce the risk of errors or omissions on their part.

Your quality control checklist should also contain details about rework or replacement costs for defective goods. This will help your supplier decide if they want to take the necessary steps to fix the defect and get the products back to you in compliance with your specifications.

When your supplier corrects a defect, it’s important to verify that the corrective actions were implemented. This is typically done at the supplier’s expense but may also be required in your contract.

You should also consider re-inspecting the reworked product units to confirm that they now meet your standards. This can be a time-consuming and costly process, but it will allow you to ensure that your supplier has taken the necessary steps to improve their quality.

Keeping your quality defect management processes up-to-date and efficient is a great way to ensure your business doesn’t miss out on any opportunities to increase its revenues. Whether you’re a small business owner or a large corporation, having a thorough quality defect tracking system can help you capture and maintain a competitive advantage.