Unit R014 - Engineering Manufacture - Topic Area 3 - Retrieval C

Quality

Quality is the standard of something when measured or compared to something else. Which product below would you class as a higher quality to the BMW?

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Answer explanation

Non of these cars are "bad" quality.

However the Rolls Royce will use significantly more refined materials and production techniques. So therefore when using the other vehicles as the measurable standard the Rolls Royce is a far better quality.

When the other vehicles are compared to their respective engineering drawings, tolerances, specifications, safety standards and other vehicles from the same class all of these vehicles would be classed as high or good quality products.

Quality

QA is the abbreviation for:

Quality _________

Quality

QC is the abbreviation for:

Quality _________

Quality

Having quality built into the design and production process is expensive. However it is fundamental in the creation of a product that sells well and is highly respected in the market. Which tools below would you expect to be used during measurement checks?

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Answer explanation

Dye penetrant can identify a defect it however does not directly measure or quantify the defect .

This will be done afterwards using measurement equipment.

Quality

Which description best explains the process of quality control?

• It is a reactive process and is end product or process orientated. It focuses on the part being manufactured and can be carried out at the end of the task or during manufacture to find a defect. This process often relies on carrying out physical checks using measurement, comparative and functionality techniques.

• This process is a preventative or proactive approach that aims to stop defects from happening in the first place rather than finding them once they have.

Quality

Which description best explains the process of quality assurance?

• It is end product or process orientated. It focuses on the part being manufactured and can be carried out at the end of the task or during manufacture to find a defect. This process often relies on carrying out physical checks using measurement, comparative and functionality techniques.

• This process is a preventative or proactive approach that aims to stop defects from happening in the first place rather than finding them once they have.

Quality

This clip shows a CMM machine taking readings from a gear. What does CMM stand for?

• Computer Measure Mode

• Co-ordinate Mapping Machine

• Co-ordinate Measuring Machine

• Computer Moving Measurements

Answer explanation

A CMM machine uses a small probe to take co-ordinates or dimensional readings from a physical product.

They are often computer controlled where the machine will move the probe automatically using sensors however they can be manually operated also.

These machines are one of the most advanced methods of dimensional measuring that engineers can use and they are incredibly accurate.

The readings will be plotted on the computer and a 3-dimensional image can be generated.

They are commonly used in temperature and atmospherically controlled rooms to prevent excess moisture and dust which can negatively impact on the readings provided by these machines.

Quality

This image shows a weld that has been inspected using X-Ray inspection. The actual weld is the white cloudy area, the deep black is the metal either side of the weld. This weld would fail as there are little deposits (inclusions) that have been trapped inside the solidified weld.

What are the advantages of using X-Ray inspection?

• Completely safe with no hazards.

• Able to identify hidden defects.

• Able to locate exact location of defects.

• Avoids damaging the product during inspection.

Answer explanation

The use of industrial radiography (X-Ray) in engineering is no different to that used in hospitals and therefore it comes with a significant radiation risk.

The operators will usually wear protective lead aprons and operate the equipment behind a lead lined door.

Quality

This clip shows a conveyor line for tomatoes. The tomatoes go through a MANUAL quality control process, where operators look for and remove unacceptable produce. What would you suggest to speed up and improve this process?

• Use X-Ray inspection

• Go-No-GO gauge

• Automatic inspection and rejection

• Digital Callipers

Answer explanation

This image shows an example of an automatic inspection and rejection machine being used.

The tomatoes move down the line at an incredibly fast pace.

Along the top of the line is a row of blue powered arms.

The tomatoes are scanned just as they approach the arms.

If any tomatoes are the wrong size or colour one of the arms will push the tomato down into an alternative path.

These tomatoes are then sold for use in sauces or animal feed as they do not pass the aesthetic requirements to be sold in the fruit and veg isles of supermarkets.

This technique allows for far greater rates of output, much increased consistency and allows staff to be used elsewhere.

Quality

A company is introducing a product and they need to develop a new production line for the products manufacture. What would you suggest the quality assurance engineers do in order to ensure the occurrence probability of defects is reduced?

• Provide training for staff on any new production machinery.

• Consider the production processes and techniques being used.

• Test and check the products.

• Plan the level, types and frequency of testing and inspection to be used.

Answer explanation

Remember quality assurance isn't about checking the product it's checking and maintaining the processes success!

Quality assurance revolves around trying to prevent and minimise defects from happening rather than actually spotting them.

Quality control will always be needed as it would be foolish to assume the production process is faultless, however quality assurance should make the quality control process much quicker and effective.

So if the staff are well trained defects should be less likely..........if the process is considered and for example machinery/CNC/Robotics are used defects should be less likely...........and finally if quality checks are put in at the the right points in production any defects that are found should be able to be handled and rectified adequately