The quality plan has defined the quality standard and the method of monitoring the quality standard in the workplace. The next step is to implement the control system so that the plan can be implemented. The system includes procedures, measuring instruments, documents, visual standards and facilities. The focus of this stage is mainly on the key features and main features. Most of these elements are identified and used by the quality department to ensure their effectiveness before control is transferred to the operator. Quality personnel also need to be trained on how to use the system effectively. In the next stage, some responsibilities will be handed over to the operator.
Quality control procedure
Explain that the quality control plan of quality control activities should be completed at a certain frequency. These activities should now be documented following formal procedures to ensure that everyone follows them correctly and consistently. These procedures include:
Non destructive testing
Pass or fail test
Procedure is a special method, and activities or processes such as inspection must be carried out. Therefore, quality control procedures should be developed to clearly define:
Who is responsible for performing quality control tasks
What are the steps, such as sampling procedures
When to execute the task, such as sampling frequency
What are the acceptable standards
Corrective actions taken if standards are not met
It is also necessary to develop references to any documents related to the procedure, such as forms to be completed.
Procedures do not only describe quality control tasks and feedback actions, such as quality inspectors telling operators or suppliers about the quality of their products. Procedures can appear in the form of organizational procedures or integrated into the quality control manual, which is more detailed than the previously formulated quality plan. It is a good idea to visually display the quality standards in preparation for operator control on the next page. Organizations that want to meet the ISO 9000 standard must ensure that all the requirements of that standard are met. It is recommended that the organization include document control techniques based on programming and authorization, such as modification status, date and information.
Develop and introduce necessary documents to record the results of quality control actions. It can include daily report, trend chart or list.
After developing these documents, make sure they:
Be as concise and user-friendly as possible
Requires minimal writing – the purpose is quality control, not management
Determine the necessity of corrective measures
Follow traceability requirements
Can be used to identify trends and improvements
The focus is to match the level of detail with process complexity and potential losses. For example, complex processes that are easy to understand are more detailed than simple processes that are easy to understand.
Suppose visual management is implemented and the team regularly measures their key performance indicators. Typical KPIs include productivity, quality, cost, delivery, safety and morale (pqcdsm for short). It may be a good idea to review quality KPIs at this stage and ensure that they support quality improvement actions. Typical measures at this stage include:
Percentage of scrap
Work teams are encouraged to be responsible for quality performance at this stage, although they may not be directly involved in quality control tasks.
Measuring instruments and facilities
Establish or upgrade quality measurement and testing facilities according to the requirements of the quality plan. The focus of this stage is mainly on the measurement of key features. Facilities include:
Non destructive testing facility
These facilities should be as close to the production area as possible and should be fed back to the production area quickly to eliminate unnecessary waste generation.
Obtain necessary tools and equipment for quality control, including scale bar, ruler, chemical analyzer and end-to-end gauge. Ensure that the equipment is properly installed and used. The key aspect to consider is the periodic calibration of measuring instruments. The reliability and predictability of measuring instruments must be higher than that of production equipment.
Quality personnel responsible for batch quality control also need training. Training depends on the requirements of the quality plan and current capabilities. The following topics may be included:
Quality management principles – provide an overview of the quality management workshop discussed in the implementation action “developing a quality strategy”
Final application of products understood by customers
Quality standards and feature classification, including acceptable tolerances
Explain quality control activities according to the quality plan
Use of instruments or test equipment
Calibration and qualification of measuring instruments
Corrective actions after problems occur
Correct use of documents
Carefully plan this training using the skills matrix and individual training needs. Review the quality function as its role changes.
The following process will provide guidance for the quality department to implement the quality control system:
Learn the quality plan and identify all key characteristics.
Develop necessary procedures for implementing quality control activities.
Record these procedures in the quality manual.
If appropriate, establish visual quality standards and display them in the workplace.
Develop and introduce necessary documents to record the results of quality control actions.
Update KPIs at all levels of the organization and focus on key quality controls.
Establish or upgrade quality measurement facilities to ensure that they quickly provide feedback on test results to production operators.
Obtain all necessary quality measuring instruments.
Introduce a system for periodic qualification review and calibration of measuring instruments.
Identify the abilities and skills required by quality personnel according to the quality plan.
Conduct gap analysis on these abilities and determine everyone’s training needs.
Describe the detailed training plan and link it to the organization’s training system.
Monitor the implementation of the plan and solve the problem areas one by one
Perform an internal audit to confirm that it has been successfully implemented.