Understanding Quality Control in Manufacturing

Importance

Quality control and quality assurance are important processes across different industries. While quality assurance is a proactive function crucial for compliance to prevent systematic issues, quality control is a reactive function that ensures the product itself is up to standard before distribution. Essentially, quality control is a necessary step in the manufacturing process because it involves product checks for things such as specifications, measurements, color and appearance, barcodes, labeling, and packaging.

Some manufacturing industry niches like pharmaceuticals, food and beverage, and chemicals are highly regulated and require strict quality control to prevent endangering the lives of consumers. Identifying defects not only ensures compliance with industry standards but also prevents extra costs and recalls. In 2023, product recalls in the United States increased by 11% and fines for defective products totaled USD 55.3 million. As such, it is crucial to undergo proper quality control processes to help prevent disruptions and support overall operational efficiency.

Common Methods for Quality Control in Manufacturing

Different manufacturing processes and organizations require their own quality control approach to ensure desirable results. As such, different methods have emerged to help ease the process of checking for product quality. Here are a few popular ones:

Quality Inspections

This method involves a straightforward inspection and assessment of all products at any stage of the production process. To identify defects, inspections can be visual, manual, or automated, using sensors and cameras to ensure consistency. Additionally, some organizations prefer to do quality control assessments using digital checklists to have more control over the process.

Six Sigma

The Six Sigma method works by defining the problem, assessing the current process, and identifying the potential cause of variations, defects, and issues. It focuses on reducing variability and defects using a data-driven approach to improve processes and involves specific steps (Define, Measure, Analyze, Improve, Control) to achieve high-quality standards.

Failure Testing

Also known as stress testing, this method evaluates product durability and performance under extreme conditions such as temperature, pressure, or tension until they break. It is a straightforward way of exposing product flaws to address potential vulnerabilities and improve product quality.

Root Cause Analysis

Root cause analysis (RCA) in manufacturing is another popular method for quality control. It is often used in the Six Sigma method because it identifies the primary cause of an issue and analyzes different factors that contribute to quality failures. RCA is important because it is focused on continuous improvement by identifying persistent or emerging problems before they can cause long-term damage.

Statistical Process Control

Statistical Process Control (SPC) uses statistical methods to monitor and control the manufacturing process. By collecting and analyzing data, manufacturers can identify trends, variations, and potential issues, allowing for adjustments before defects occur.

It is highly dependent on quantitative data and can identify tolerable limits in product variations. This methodology leads to discovering problems that will be addressed through corrective measures.

Best Practices

Besides identifying a quality control method that works for their organizational needs, manufacturers need to support this process by implementing practices that deliver top-quality products. Here are some key best practices:

• Define Clear Quality Standards: Set specific, measurable quality standards aligned with industry regulations and customer expectations. Thoroughly document these standards so that all team members understand the requirements and are aligned with overall manufacturing goals.

• Implement Standard Operating Procedures (SOPs): Develop and enforce SOPs to standardize production processes. SOPs reduce variation, improve efficiency, and ensure that all employees follow consistent practices.

• Use Data for Decision Making: Collect and analyze data throughout the manufacturing process to identify patterns and root causes of defects. Conduct routine inspections and audits to ensure accuracy over observations and use real-time monitoring systems to track key quality metrics at every stage.

• Invest in Employee Training: Regular training on quality standards, inspection techniques, and equipment use ensures that employees are skilled and knowledgeable about maintaining product quality. Empowering employees with problem-solving skills also helps identify and address issues early.

• Listen to Customer Feedback: Gather and analyze customer feedback regularly. Use this information to make necessary quality adjustments and enhance product reliability and customer satisfaction.