Rigorous testing and inspection of materials is crucial for companies to deliver high-quality products to customers. There are several key steps involved in materials quality control:
- Setting Specifications
Engineering and product teams will determine the critical specifications required for purchased materials. This includes physical, chemical, and performance requirements that suppliers must meet. Clear specifications are essential for quality control.
- Supplier Qualification
Potential suppliers are evaluated to ensure they can consistently meet specifications. This may involve auditing facilities, processes, and quality systems. Only approved suppliers are used since the incoming quality of materials heavily depends on the supplier’s capabilities.
- Incoming Inspection
When materials are received, inspections are conducted to verify conformance to specifications. This typically includes visual checks, dimensional measurements, testing chemical composition, and performance testing. Sampling plans may be used to pull random samples from larger batches for inspection.
- Process Control
During production, processes are continuously monitored to ensure they remain in control. This can involve statistical process control tracking key process parameters over time to identify when a process may be deviating from target conditions. Operators are trained to inspect in-process materials.
- Final Testing
Finished products undergo inspections and tests to confirm quality prior to release. Examples include appearance, packaging, dimensions, performance, and life testing. For critical product characteristics, 100% inspection may be conducted.
- Documentation
Extensive records are maintained for each step of production and testing. This traceability enables root cause analysis if any non-conformances are found. Records confirm due diligence was followed in verifying quality.
Rigorous quality control requires investment, but prevents defects, hazards, and failures down the line. Setting clear specifications, verifying supplier capabilities, robust inspections, consistent process control, and complete documentation are critical for delivering high-quality materials and products.