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Poor Quality Costs? What are Yours?

What The @%&# is Statistical Quality Control, AQL’s, Pareto and P-Chart’s?

· Shop Floor,Labor Compliance,Payroll,Efficiency,Quality Control

An Android Tablet Based Quality Control App

How much is it costing you to NOT have a Statistical Quality Control program? Are you consumed with rework, shortages, downgrading, delays, all of which are preventable internal failure quality control costs

What are your costs for external quality control failures? Those failures that reach your customers? For example, complaints, losses due to sales reductions, customers’ bad will, etc.

Statistical Quality Control is an integral part of Six Sigma. Using Byte’s Quality Control App, you can facilitate your Six Sigma goals and objectives.

Byte’s Android™ tablet based Quality Control App provides you the tools to do Statistical Quality Control (SQC) analysis using AQL tables as a guide for sampling and inspection. The results can be shown in our Pareto and P-Charts.​

Who can use Byte’s Quality Control App?

Any company that needs to track their quality control statistically, including all manufacturers, contractors, and brands that manage their sourcing and quality.

Statistical Quality Control

Statistical Quality Control (SQC) is the use of statistical methods to measure and improve the quality of manufacturing processes and products by quality professionals. SQC can be divided into three categories.

  1. Descriptive statistics
  2. Statistical process control (SPC)
  3. Acceptance sampling

What Is Acceptance Sampling?

When companies are producing thousands of units they cannot possibly test every one of its products due to the volume, this is solved by Acceptance Sampling. There is a specified degree of statistical certainty when a company can measure the quality of a sampling without having to test every unit.

The sampling quantity is determined by using an AQL (Acceptance Quality Limit) table.

What Does Acceptance Quality Limit Mean?

‘AQL’ stands for ‘Acceptance Quality Limit’, and is defined as the “quality level that is the worst tolerable” in ISO 2859-1. It represents the maximum number of defective units, beyond which a batch is rejected. Importers usually set different AQLs for critical, major, and minor defects². Byte offers four defect levels.

Within Byte, you and your customer determine an acceptable quality level. The AQL table can be configured by customer, style or cut.

Once your sampling is complete you’ll want to report your findings using our Pareto charts and P-Charts.

Pareto Chart

The Pareto Chart answers the largest issues facing your business by utilizing the Pareto 80/20 Rule. Twenty percent (20%) of sources are causing eighty percent (80%) of the problems. You’ll know exactly where to focus your efforts to achieve the greatest improvements. With Byte, you’ll know your issues by defect types, by operator, by machine, etc. The Pareto Chart can be by date, employee, sew line, skill, style, defect type and contract.

P-Chart

Like other types of control charts, the P-Chart provides information about the variation in process performance. Six Sigma practitioners use it to distinguish special cause and common cause variation and identify performance trends, so they can determine the appropriate approach for improvement.³

Byte can display the P-Chart by employee, day, week, sew line, contract and many other focus points.

Next Steps?

The fact is, “business processes with better process sigma will have significantly lower prevention and appraisal costs. Although you will never fully eliminate appraisal and prevention costs (as opposed to failure costs that in an ideal zero defect world would also be zero), their reduction due to better process performance will be significant.” ⁴

Call/email us today so we can understand what your quality control goals and challenges are so you can start measuring and quantifying your improvements.

References:

  1. Cost of Quality: Not Only Failure Costs, Arne Buthman, https://www.isixsigma.com/implementation/financial-analysis/cost-quality-not-only-failure-costs/
  2. What is the “AQL” (Acceptance Quality Limit) in simple terms? By Renaud Anjoran https://qualityinspection.org/what-is-the-aql/
  3. Using a P Chart For Quality Control, by: Heidi Wiesenfelder, edited by: Michele McDonough http://www.brighthubpm.com/six-sigma/65049-using-a-p-chart-for-quality-control/
  4. Cost of Quality: Not Only Failure Costs, Arne Buthman, https://www.isixsigma.com/implementation/financial-analysis/cost-quality-not-only-failure-costs/    
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