“Quality Control” in Electrical and Electronic Manufacturing

‘Quality of a Product or materials’ depends on given standards but also depends on manpower’s handling, manufacturing with a given specification. 

I have seen at many assembly line in manufacturing industry has one or two more  extra manpower for cleaning and that’s indicate how much pollution is there in industry and how governments has given “pollution clearance”.

Many Clients and Customers demanded ‘ imported materials’ for their products to be manufacturing here in India .

There are many industries spending lots of money for the name of QA/QC but QA/QC failed to take necessary action. True speaking they are afraid to ‘hold’ and ‘reject’ the lots. I remember when my Boss QA/QC Manager always remind me that “ don’t work like government offices and like daily routine’’ I still follow his advice and try to do something new and different in my working environment.

“Quality Control” isn’t limited to maintain for a given specification and follow standard but also to work hard for products, materials and processes improvements and also for ‘ innovation’.

“Quality Control” is also related to ‘calibration’ , ‘fields  complaints’, ‘Quality analyzed’ , ‘ reduce rejection rate’ , reduced and analysis for reasons of field complaints’.Work hard for why output of M/C hasn’t producing parts as per given specification.It has been observed the efficiency and maintenance of M/C that’s also impact on ‘Quality’.It is also to know and analyze for reasons of rejection from Mould. Try to reduce Moulding defects.

We should find more testing instruments for quality check, evaluations of materials. We should collect data after quality check of materials and products from instruments and analyze that data with Statistical tools and find where is more variations in data of that products/ materials and create a “ team’’ and assign him to work hard so that could reduce variations by using different tool of quality control and Statistical tools.

Every morning should analyze ‘where, why and how’ materials found out of spec and what’s the reason of Products reloading after repairing and try to reduce it with the help of suppliers and asked him necessary corrective action for current rejected lot and next lot should be supplied to Factory after taking necessary corrective action.

When next lot arrived from that suppliers it’s become very necessary if ‘for Receiving Inspection’to validate and verify that what promises has done by suppliers he did or not. If not hold the lot and try to find another supplier for that materials/Products.

Factory should also work hard and always try to search alternative suppliers with their standard of quality and at reduced price.

Factory should focus on processes for their improvements and reduced variations.

I have seen that ‘ quality of imported materials and local’ has differences in their quality.

This is because every country has his own Standard of quality . That’s why exporting to other countries has to maintain good quality to pass in imported countries Lab.

Prices is also factor in a quality. Sometimes we forget about quality when we’re getting cheap and cheaper price.But it’s challenging and most important because of this reasons there’s a quality department to maintain quality of cheap prices materials and products.

Quantity VS Quality : Sometimes Production pressurized for more quantity for out put instead of caring quality.In this case good decisions should be taken by quality personal by checking more & more quantity to confirm and become confident to explain seniors about reasons of rejection and defects.Sometimes minor rejection can be ignored but can’t take risks with critical and major defects and take necessary and corrective action to maintain given standard of quality.

It has been observed that exporting goods Countries to Countries will find variations in quality as well as in Price.It has been observed that “Made in China” products and raw materials hasn’t good reputation of quality but because of simplicity, with reasonable prices and within average quality it’s products and materials are too much demanding in the world compared to other Countries products/ materials and Machinery.

During my tenure in a Factory of Saudi Arabia as a ‘Receiving Inspection Engineer’ I found this process to whom I was a ‘Process Owner’ was a full fledge systemic process only time to time need to evaluate, updates and make changes.As a “ Process owner “ I have to monitor received every news lots of raw materials should properly inspected, tested and evaluated so that Assembly line should run smoothly without finding any defects and rejection at their.Whatever defects and rejection found at ‘Receiving Area’ Production and Production planning should planned alternative sources of that raw materials for the sake of continuous and smooth running of production at Assembly line.

My QC manager always advise me that you take care of Sample evaluations of alternative of regular suppliers and closing of ‘Suppliers Corrective action report’.Most of materials sourced from outside countries. Most important suppliers were very serious during rejection of their materials . They arrived and take necessary action of next lot & pay compensation and even pay for ‘segregation’ charges.

Next during my 4- years stay of China where I visited for ‘Products Audit’ and ‘Factory audit’ almost more than 100 Factories which was included a small, medium and large Factories. Most of Factories has only “Final assembly line” which’s partially manufacturing process but those Factories can easily found raw materials of their products near to their Factories that’s why low prices of their products are available for their customers.Even 24 hrs non-interrupted Electricity is available for Industry. Skilled manpower is easily available , international customers can be easily found at digital platform like “Alibaba” and different fairs quarterly, half yearly and yearly conducted like “Canton fair” in Guangzhou where many Business owners,CEO attended from whole part of the world for sourcing of their shipments, products, materials and Machinery.Most of Factories are working for their international markets demands of their products. If they have any customers who placed order one time it doesn’t mean that he will order next shipment. Customers has many options to choose their OEM in China because of many Factories are available for one products and for one raw materials.Many Factories doesn’t want a Fixed assets for their manufacturing industry because when their is no order money and maintenance is required for that assets.Even many Countries are avoiding to invest in buying and setup of heavy Machineries for their manufacturing unit. Most of them trying to do tradings either domestic or international.