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Production management technology: incoming material inspection

IQC (incoming quality control) is the first level to control the quality of enterprise products before production. If the unqualified products are put into the process, it will lead to the disqualification of the process or the final products, resulting in huge losses. IQC not only affects the quality of the company’s final products, but also affects various direct or indirect costs.

In the manufacturing industry, the four main items that have a direct impact on product quality are usually design, incoming materials, manufacturing process and storage and transportation. Generally speaking, design accounts for 25%, incoming materials 50%, manufacturing process 20% and storage and transportation 1% to 5%. To sum up, the incoming material inspection plays an overwhelming role in the company’s product quality, so the incoming material quality control should be upgraded to a strategic position.

The core of quality management is quality, the basis is full participation, the purpose is to satisfy customers, and the ultimate goal is to form a long-term successful management approach. To sum up, quality management generally includes three aspects, namely incoming quality management, process quality management and delivery quality management. Enterprises can break through quality management from the above three aspects and find the best way. In this paper, we will introduce how to do a good job of incoming inspection.

What is IQC?

IQC (incoming quality control) refers to the quality confirmation and inspection of the purchased raw materials, components or products. That is to say, when the supplier sends the raw materials or components, the quality is inspected by sampling, and finally the batch of products is judged to be received or returned.

Significance of incoming material inspection

IQC is the first level to control the quality of products before production. Its purpose is to move the quality control forward, find the quality problems in the front, reduce the quality cost and achieve effective control. If the unqualified products are put into the process, it will lead to the disqualification of the process or the final product, resulting in huge losses. IQC not only affects the quality of the company’s final products, but also affects various direct or indirect costs.
In the manufacturing industry, the four main items that have a direct impact on product quality are usually design, incoming materials, manufacturing process and storage and transportation. Generally speaking, design accounts for 25%, incoming materials 50%, manufacturing process 20% and storage and transportation 1% to 5%. To sum up, the incoming material inspection plays an overwhelming role in the company’s product quality, so the incoming material quality control should be upgraded to a strategic position.

Responsibilities of incoming material inspector

Incoming inspection

The main work is the incoming material inspection, and IQC inspection can be described as the confirmation of all or main characteristics of the outsourcing materials with reference to the relevant standards of the materials; Or confirm whether it meets the use requirements.

Deal with material quality problems

IQC should also track and deal with the quality problems found in the inspection process, as well as the major material quality problems fed back by production and market, and establish preventive measures within IQC.

Statistics and feedback of material quality problems in the whole process

Statistic the quality data in the process of receiving and inspecting the incoming materials, and feed back to the relevant departments in the form of weekly and monthly reports, as the basis for the supplier’s incoming material quality control and management.

Participate in process optimization of material department

Participate in the process optimization of logistics control, and put forward suggestions and opinions on the process optimization of logistics and material inspection.

Introduction of four sampling methods for incoming material inspection

IQC often encounter various defects during incoming inspection. During the inspection, it is necessary to inspect from the whole incoming material and sample extraction. We mainly introduce the sampling method of IQC.

Sampling method commonly used in IQC incoming inspection

Hierarchical sampling

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If the incoming goods are placed in layers or in order, the hierarchical sampling method can be used for sampling. See the following illustration. For example, the resistor, capacitance and other patch materials are placed in multiple volumes, and the cartoon box is stacked in layers, etc., then it is applicable.

Diagonal sampling

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For the goods in the vertical and horizontal, orderly and consistent, the diagonal sampling method can be used for sampling. See the following illustration. This method is applicable if the incoming materials such as pallets are used for holding or tiling.

Triangle sampling

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If the incoming goods are placed on the same plane, the triangle sampling method can be used for sampling. See the following illustration. The law is also applicable to the circumstances described in the second part.

S-type sampling method

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If the incoming goods are placed on the same plane, the S-shaped sampling method can also be used for sampling. See the following illustration.
IQC is generally responsible for the quality control of purchased materials, including inspection and statistical analysis of various data. The common reports are generally inspection reports, monthly or annual summary of incoming inspection results, material ppm reports, etc. There are many reports. It can be analyzed and processed by some software systems, which can achieve paperless, labor cost saving, improve the response ability to quality problems, shorten the reaction time, and automatically collect the test data and generate the report required by IQC, and improve the efficiency of the staff.

Working principle

IQC is a window for the company to deal with suppliers, and it is also the gateway to control the quality of suppliers. How IQC works is directly related to the company’s product quality cost and the company’s impression among suppliers.

Rigorous sampling

Sampling inspection is a statistical probability, and there is a risk. This risk may put the defective products on the production line due to missing inspection, or reject the qualified products, thus indirectly causing the loss of the company. Therefore, when sampling, we must try our best to let the samples reflect the quality status of the mother. In the sampling plan, according to the current international or national standards, the risk rate can be controlled below 5%. However, in the process of sampling, the randomness of the population may not be enough due to personal preference, so we should pay special attention to the preciseness of sampling methods.

Judge quality objectively and fairly

IQC personnel often contact with suppliers, forming a “emotional atmosphere”, which is easy to form a subjective consciousness in the inspection, resulting in differences in the judgment standards of suppliers.
Under the influence of personal mood, if you are in a good mood, you may be more serious, and the inspection and judgment are more cautious; A bad mood may be to fix the world at a glance.
Affected by the personality of the inspectors, people who are anxious are easy to be subjective in judgment, so we should pay attention to objectivity and fairness. If the unqualified batch is put into the manufacturing process and the raw material problem occurs, the first thing to be investigated is the responsibility of IQC personnel.

Respect suppliers

Judging by comprehensive factors

During the inspection, sometimes there are conflicts in quality, time, cost and efficiency. For example, the raw materials need to be put on line urgently, but the inspection finds that there is a little “small problem” which can not be accepted according to the original standard. The company’s purchasing strategy is to use the materials with lower prices. Although there are differences with the original quality objectives, it is still possible to accept them.

Try not to be special

The identification is clear during the inspection
Label identification is used to distinguish the products to be inspected, defective products, qualified products, etc., preferably pasted on the colored label.

Teach you to distinguish QC, IQC, IPQC and QA.

Quality management involves a lot of English abbreviations, how to distinguish their meaning, I hope this article can help you!
QC: quality control, quality control, product quality inspection, analysis and improvement of quality problems and control of unqualified products. It generally includes:

  • IQC (incoming quality control)
  • IPQC (in process quality control)
  • FQC (final quality control)
  • OQC (out going quality control)

QC focuses on the product rather than the system (system), which is the main difference between QC and QA. The purpose is consistent with QA, which is “to meet or exceed customer requirements.”
QA: quality assurance, through the establishment and maintenance of quality management system to ensure that there is no problem with product quality. Generally including system engineer, SQE (Supplier Quality Engineer), CTS (customer technical service personnel), 6Sigma engineer, calibration and management of measuring instruments. QA should not only know where the problems are, but also know how to formulate solutions to these problems and how to prevent them in the future. QC should know that if there are problems, it is necessary to control them, but it is not necessary to know why to control them in this way.
For example, QC is the police and QA is the judge. QC just needs to catch those who violate the law. It can’t prevent others from committing crimes and convicting them. The judge is to make laws to prevent crimes and pronounce the results according to the law.
To sum up, QC: it is mainly the quality inspection activities after the event. The default error is allowed, and the error is expected to be found and selected. QA is mainly the quality assurance activities in advance, focusing on prevention, hoping to reduce the probability of errors.
QC is to make the product meet the quality requirements of the operation technology and activities, it includes inspection, correction and feedback, such as QC inspection found that the defective products will be removed, and then the bad information feedback to the relevant departments to take improvement measures. Therefore, the scope of QC control is mainly in the factory, and its purpose is to prevent unqualified products from entering, transferring and leaving the factory, to ensure that the products meet the quality requirements and only qualified products can be delivered to customers.
QA is to provide trust to meet the customer’s requirements. Even if the customer is sure that the product you provide can meet his requirements, it is necessary to leave evidence from the beginning of market research and the subsequent stages of reviewing customer requirements, product development, order receiving and material purchasing, incoming inspection, production process control and delivery, after-sales service, etc., to prove that every step of the factory’s activities are carried out according to the customer’s requirements.
The purpose of QA is not to ensure the quality of products, which is the task of QC. QA is mainly to provide assurance, so it is necessary to manage the whole process from understanding customer requirements to after-sales service, which requires enterprises to establish a quality control system, formulate corresponding documents, standardize the activities of each process, and leave evidence for the implementation of activities, so as to provide trust.
This kind of trust can be divided into internal and external two kinds: the external one believes that the factory produces and delivers products according to its requirements, even if the customer is at ease; Internal is to let the factory boss rest assured, because the boss is the first person responsible for product quality, and he should take full responsibility for product quality accidents, which is also the main requirement for countries to formulate product quality laws, so as to urge enterprises to really pay attention to quality. Therefore, in order to avoid undertaking quality responsibility, the boss must standardize various activities with documents and leave evidence.
However, it is impossible for the boss to know whether the internal personnel of the factory operate according to the requirements of the documents one by one, which requires QA to audit on his behalf to find out whether the requirements of the documents have been complied with, so as to make the boss believe that the activities of the factory are carried out according to the provisions of the documents and make him feel at ease.
Therefore, the main difference between QC and QA is: the former is to ensure that the product quality meets the requirements, while the latter is to establish a system and ensure that the system operates according to the requirements, so as to provide internal and external trust. At the same time, QC and QA have the same point: both QC and QA need to verify. For example, QC testing products according to the standard is to verify whether the products meet the specified requirements, QA internal audit is to verify whether the system operation meets the standard requirements, and QA delivery audit and reliability test is to verify whether the products have carried out various activities according to the regulations and whether they can meet the specified requirements, To ensure that the products delivered by the factory are qualified and comply with relevant regulations.
The most important responsibility of QC is to monitor the finished products (mainly including raw material, in-process goods, finish goods, in-process audit), focusing on detecting defects through sample inspection.
QC can be divided into IPQC and IQC:

  • IPQC: in process quality control
  • IQC: in come quality control

Its responsibilities are as follows:
Responsibilities of IPQC

  • 1. Inspect the products in the production process and make records.
  • 2. Fill in the inspection report according to the inspection record.
  • 3. Put forward improvement countermeasures for the problems found in the inspection.

Responsibilities of IQC

  • 1. Inspect raw materials in strict accordance with inspection standards.
  • 2. Fill in the inspection record truthfully.
  • 3. Maintenance of testing equipment.
  • 4. Report of abnormal raw materials.
  • 5. Identification of raw materials.
  • 6. Sign and receive the inspection report of warehouse material man.
  • 7. Be responsible for re checking the materials stored in the warehouse for the quality problems complained by the production line.

QA is quality supervision / monitoring

  • 1. Be responsible for the overall work of the Department, organize the implementation of GMP related quality management. regulations, and timely put forward product quality opinions and improvement suggestions to the enterprise leaders.
  • 2. Ensure that our products are produced in accordance with GMP requirements.
  • 3. Be responsible for supervising the implementation, correction and prevention of quality related people and things in the whole enterprise.
  • 4. The instructions beneficial to production configuration shall be reviewed and approved after being reviewed and signed by the designated personnel of the Department.
  • 5. Review and approve the test results.
  • 6. Audit the pilot plan and conclusion of new product development and process improvement.
  • 7. Review and report the relevant technical and quality written materials to the drug regulatory department.
  • 8. Examine and approve the batch records and make the conclusion whether the finished products are delivered.
  • 9. Organize the formulation of quality standards and other documents for raw and auxiliary materials and packaging materials.
  • 10. Review the handling procedure of unqualified products.
  • 11. For the needs of quality management, organize the preparation of new technical standards or discuss the revision of technical standards with relevant departments.
  • 12. Audit the production process procedures, batch production records and batch packaging records of each product, and decide the distribution of finished products.
  • 13. Handle the product quality problems complained by users, assign personnel or visit users in person. Hold a meeting internally, study and improve the quality problems with relevant departments, and report the complaints and handling results to the person in charge of the enterprise in writing.
  • 14. Regularly (at least once a year) carry out comprehensive GMP inspection with chief engineer’s office and production department, and timely report the inspection to the person in charge of the enterprise.

Source: Network Arrangement – China Flange Manufacturer – Yaang Pipe Industry (www.epowermetals.com)

(Yaang Pipe Industry is a leading manufacturer and supplier of nickel alloy and stainless steel products, including Super Duplex Stainless Steel Flanges, Stainless Steel Flanges, Stainless Steel Pipe Fittings, Stainless Steel Pipe. Yaang products are widely used in Shipbuilding, Nuclear power, Marine engineering, Petroleum, Chemical, Mining, Sewage treatment, Natural gas and Pressure vessels and other industries.)

If you want to have more information about the article or you want to share your opinion with us, contact us at sales@epowermetals.com

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