QA/QC Training Course

1. Introduction to QA/QC

1.1 Quality Fundamentals

• Quality definition including (fitness for purpose, conformance to requirements, customer satisfaction, value delivery, excellence)

• Quality assurance versus quality control including (prevention versus detection, proactive versus reactive, process versus product, system versus inspection)

• Quality concepts including (quality standards, specifications, tolerances, acceptance criteria, fitness for use, conformance)

• Quality importance including (customer satisfaction, cost reduction, reputation, competitive advantage, compliance, risk mitigation)

• Quality responsibility including (management commitment, employee ownership, shared accountability, quality culture, organizational responsibility)

1.2 Quality Management Principles

• Customer focus including (requirement understanding, expectation management, satisfaction measurement, value delivery, relationship building)

• Process approach including (systematic processes, interconnections, inputs and outputs, efficiency, value creation)

• Evidence-based decisions including (data collection, measurement, analysis, factual basis, informed decisions)

• Continuous improvement including (ongoing enhancement, problem-solving, innovation, efficiency gains, excellence pursuit)

• People engagement including (competence, empowerment, involvement, recognition, team contribution)

1.3 Quality Standards and Compliance

• ISO 9001 basics including (quality management system, process approach, customer focus, improvement, international standard)

• Industry standards including (sector-specific requirements, technical standards, safety standards, regulatory compliance, best practices)

• Specifications including (product specifications, material specifications, process specifications, test methods, acceptance limits)

• Regulatory requirements including (legal compliance, mandatory standards, safety regulations, environmental requirements, certification)

• Quality documentation including (quality manual, procedures, work instructions, forms, records, document hierarchy)

2. Quality Assurance Planning

2.1 Quality Planning

• Quality objectives including (measurable goals, performance targets, improvement aims, strategic alignment, SMART objectives)

• Quality plan development including (project quality plan, inspection and test plan, resource planning, timeline, deliverables)

• Process planning including (process definition, control points, inspection stages, acceptance criteria, documentation requirements)

• Resource requirements including (personnel, equipment, tools, facilities, materials, competency needs, adequate provision)

• Risk assessment including (potential quality risks, failure modes, preventive measures, contingency planning, risk mitigation)

2.2 Quality Control Points

• Control point identification including (critical operations, key processes, inspection stages, hold points, witness points)

• Inspection stages including (receiving inspection, in-process inspection, final inspection, pre-shipment inspection, systematic verification)

• Hold points including (mandatory inspection, approval requirement, process halt, verification before proceeding, critical gates)

• Witness points including (customer presence, third-party verification, documentation, notification requirements, collaborative verification)

• Sample points including (sampling locations, frequency, quantity, representative samples, statistical validity)

2.3 Quality Documentation

• Quality procedures including (inspection procedures, test procedures, sampling procedures, work instructions, step-by-step guidance)

• Inspection and test plans including (ITP development, inspection points, acceptance criteria, frequency, responsibility assignment)

• Quality records including (inspection records, test reports, certificates, checklists, traceability, evidence documentation)

• Document control including (document approval, version control, distribution, obsolete document removal, accessibility)

• Record retention including (storage requirements, retention periods, retrieval systems, protection, regulatory compliance)

3. Quality Control Techniques

3.1 Inspection Methods

• Visual inspection including (appearance check, defect identification, workmanship assessment, surface quality, visual standards)

• Dimensional inspection including (measurement verification, tolerance checking, dimensional accuracy, specification conformance, precise measurement)

• Functional testing including (performance verification, operational testing, functionality check, system testing, capability validation)

• Non-destructive testing including (NDT methods, ultrasonic testing, radiography, magnetic particle, penetrant testing, internal inspection)

• Destructive testing including (material testing, strength testing, sample destruction, properties verification, definitive analysis)

3.2 Measurement and Testing

• Measurement principles including (accuracy, precision, resolution, calibration, measurement uncertainty, reliable results)

• Measuring instruments including (calipers, micrometers, gauges, measuring tapes, test equipment, proper tools, appropriate selection)

• Measurement techniques including (proper usage, reading techniques, measurement procedures, error minimization, consistent methods)

• Test methods including (standard test methods, test procedures, test conditions, acceptance criteria, result interpretation)

• Calibration including (calibration requirements, frequency, standards traceability, calibration records, measurement assurance)

3.3 Sampling and Acceptance

• Sampling principles including (representative samples, random sampling, sampling plans, statistical basis, valid conclusions)

• Acceptance sampling including (AQL, lot inspection, sample size, acceptance number, rejection number, statistical decision)

• Sampling standards including (ISO 2859, ANSI/ASQ Z1.4, sampling tables, inspection levels, switching rules)

• Sample selection including (random selection, systematic sampling, sampling locations, unbiased selection, representative coverage)

• Lot disposition including (acceptance, rejection, 100% inspection, reduced inspection, normal inspection, tightened inspection)

4. Inspection and Testing Procedures

4.1 Receiving Inspection

• Receiving process including (material receipt, documentation verification, quantity check, damage assessment, acceptance decision)

• Supplier documentation including (packing list, certificates, test reports, material certificates, compliance verification, documentation review)

• Visual inspection including (packaging condition, labeling, identification, obvious defects, damage detection, preliminary assessment)

• Sampling inspection including (sample selection, inspection execution, acceptance criteria, lot disposition, statistical sampling)

• Non-conformance handling including (rejection, segregation, supplier notification, disposition, corrective action request)

4.2 In-Process Inspection

• Process monitoring including (ongoing verification, parameter checking, control verification, trend observation, real-time monitoring)

• First-off inspection including (initial production check, setup verification, process validation, before mass production, quality assurance)

• Patrol inspection including (periodic checks, roving inspection, process verification, random sampling, continuous vigilance)

• Critical point inspection including (key operations, quality gates, hold points, mandatory verification, critical control)

• Work-in-progress inspection including (intermediate stages, process conformance, defect detection, timely intervention, prevention focus)

4.3 Final Inspection

• Final inspection planning including (inspection scope, acceptance criteria, test requirements, documentation, comprehensive verification)

• Completeness verification including (all operations completed, all tests passed, documentation complete, ready for delivery)

• Functional testing including (performance verification, operational check, specification conformance, capability validation, full functionality)

• Cosmetic inspection including (appearance, finish quality, workmanship, customer-visible quality, aesthetic standards)

• Documentation completion including (inspection records, test results, certificates, final approval, release authorization)

5. Non-Conformance Management

5.1 Non-Conformance Identification

• Defect classification including (critical defects, major defects, minor defects, severity assessment, impact evaluation)

• Non-conformance types including (dimensional non-conformance, material defects, process deviations, documentation errors, varied issues)

• Detection methods including (inspection, testing, customer feedback, audit findings, self-identification, multiple sources)

• Documentation including (NCR forms, non-conformance reports, defect description, evidence, photographic documentation)

• Segregation including (identification, isolation, quarantine, controlled area, contamination prevention, clear marking)

5.2 Non-Conformance Handling

• Immediate actions including (containment, customer protection, production hold, impact limitation, rapid response)

• Disposition options including (use-as-is, rework, repair, scrap, return to supplier, concession, informed decision)

• Rework procedures including (rework instructions, verification after rework, re-inspection, acceptance, quality assurance)

• Scrap management including (scrap authorization, disposal, scrap records, cost tracking, waste management)

• Concession requests including (deviation request, customer approval, engineering approval, documented acceptance, controlled exception)

5.3 Corrective and Preventive Actions

• Root cause analysis including (problem investigation, cause identification, 5 Whys, fishbone diagram, systematic analysis)

• Corrective action including (immediate correction, root cause elimination, recurrence prevention, action implementation, verification)

• Preventive action including (potential problem identification, proactive measures, risk mitigation, prevention focus, forward-thinking)

• Action verification including (effectiveness check, follow-up inspection, performance monitoring, validation, sustained resolution)

• Trend analysis including (pattern identification, recurring issues, systematic problems, data analysis, proactive improvement)

6. Measurement System Analysis

6.1 Measurement System Basics

• Measurement system including (instrument, operator, procedure, environment, part, complete system)

• Measurement variation including (accuracy, precision, repeatability, reproducibility, stability, linearity, bias)

• Measurement capability including (adequate discrimination, resolution, measurement uncertainty, fitness for purpose)

• Calibration requirements including (calibration frequency, calibration standards, traceability, calibration status, verification)

• Measurement error including (systematic error, random error, error sources, error minimization, quality impact)

6.2 Gage R&R Study

• Gage Repeatability and Reproducibility including (measurement system analysis, variation assessment, operator effect, equipment effect)

• Study methodology including (data collection, multiple operators, multiple parts, replications, systematic approach)

• R&R calculation including (repeatability calculation, reproducibility calculation, total variation, percentage contribution, capability assessment)

• Interpretation including (acceptable criteria, adequate measurement system, improvement needs, decision-making, system validation)

• Improvement actions including (operator training, equipment maintenance, procedure clarification, system enhancement, capability improvement)

7. Quality Tools and Techniques

7.1 Seven Basic Quality Tools

• Check sheets including (data collection, tally marks, structured recording, pattern observation, simple tool)

• Histograms including (data distribution, frequency plot, process capability, visual representation, pattern recognition)

• Pareto charts including (prioritization, 80/20 rule, vital few, problem ranking, focus identification)

• Cause and effect diagram including (fishbone diagram, Ishikawa diagram, cause identification, systematic analysis, problem-solving)

• Scatter diagrams including (correlation, relationship analysis, variable interaction, pattern identification, causal exploration)

• Control charts including (process monitoring, variation tracking, stability assessment, trend detection, statistical control)

• Flowcharts including (process mapping, workflow documentation, step visualization, process understanding, improvement identification)

7.2 Problem-Solving Methods

• 5 Whys technique including (root cause drilling, iterative questioning, simple method, cause identification, problem depth)

• 8D methodology including (team approach, problem description, containment, root cause, corrective action, verification, prevention, recognition)

• PDCA cycle including (Plan-Do-Check-Act, continuous improvement, systematic approach, learning cycle, iterative process)

• Six Sigma DMAIC including (Define, Measure, Analyze, Improve, Control, structured methodology, data-driven improvement)

• Brainstorming including (idea generation, team participation, creative thinking, solution development, collaborative approach)

7.3 Statistical Process Control Basics

• SPC concepts including (process variation, common cause, special cause, statistical limits, control understanding)

• Control charts including (variables charts, attributes charts, centerline, control limits, out-of-control signals)

• Process capability including (Cp, Cpk, capability indices, specification limits, process performance, statistical assessment)

• Sampling plans including (sample size, frequency, acceptance criteria, statistical basis, economical inspection)

• Data analysis including (trend identification, pattern recognition, statistical interpretation, decision support, informed action)

8. Quality in Manufacturing

8.1 Manufacturing Quality Control

• Process control including (parameter monitoring, process adherence, control verification, stability maintenance, consistent output)

• Work instructions including (step-by-step procedures, visual aids, clear guidance, standardization, operator support)

• First Article Inspection including (FAI procedure, initial production verification, dimensional check, material verification, approval)

• Production monitoring including (ongoing inspection, parameter checking, defect tracking, quality assurance, real-time control)

• Operator inspection including (self-inspection, workmanship standards, quality awareness, accountability, first-line defense)

8.2 Material and Component Control

• Material identification including (labeling, traceability, lot numbers, material certificates, clear identification, tracking)

• Material storage including (proper conditions, environmental control, shelf life, FIFO, contamination prevention, integrity maintenance)

• Material handling including (handling procedures, damage prevention, cleanliness, proper equipment, care requirements)

• Traceability including (batch tracking, serial numbers, genealogy, recall capability, complete records, upstream-downstream visibility)

• Material certification including (mill certificates, test reports, conformance certificates, material verification, documentation)

8.3 Workmanship Standards

• Workmanship criteria including (visual standards, acceptance limits, reference samples, quality levels, clear expectations)

• Visual standards including (good samples, defect samples, limit samples, photographic standards, reference materials)

• Surface finish including (finish requirements, roughness standards, appearance criteria, coating quality, aesthetic standards)

• Assembly quality including (fit and alignment, fastener torque, joint quality, installation correctness, functional integrity)

• Cleanliness including (contamination control, cleaning procedures, cleanliness inspection, acceptance criteria, quality protection)

9. Documentation and Record Keeping

9.1 Quality Records

• Inspection records including (inspection checklists, measurement data, test results, inspector signature, date, comprehensive documentation)

• Test reports including (test description, results, acceptance criteria, conformance statement, authorized signature, official documentation)

• Certificates including (material certificates, test certificates, conformance certificates, calibration certificates, third-party certificates)

• Non-conformance records including (NCR documentation, disposition records, corrective actions, verification, complete history)

• Traceability records including (material traceability, process records, inspection history, complete genealogy, full visibility)

9.2 Document Control

• Document approval including (review process, authorization, approval signatures, controlled issuance, proper authorization)

• Version control including (revision identification, version numbers, change tracking, supersession, current version identification)

• Document distribution including (controlled copies, distribution list, receipt acknowledgment, availability, access management)

• Obsolete documents including (removal from use, archival, destruction, prevention of unintended use, document lifecycle)

• Electronic documents including (electronic signatures, access control, backup, version control, security, digital management)

9.3 Data Management

• Data collection including (systematic collection, data integrity, timely recording, complete information, accurate capture)

• Data organization including (database structure, filing systems, searchability, logical organization, efficient retrieval)

• Data analysis including (trend analysis, pattern identification, statistical analysis, insight generation, decision support)

• Data reporting including (quality reports, metrics, dashboards, management reporting, stakeholder communication)

• Data retention including (retention requirements, archive systems, regulatory compliance, accessibility, secure storage)

10. Supplier Quality Management

10.1 Supplier Quality Assurance

• Supplier qualification including (capability assessment, quality system review, approval process, qualified supplier list)

• Supplier requirements including (quality specifications, documentation requirements, certification needs, delivery expectations, clear communication)

• Purchase order review including (specification review, requirement clarity, acceptance criteria, inspection requirements, contractual clarity)

• Supplier monitoring including (performance tracking, quality metrics, delivery performance, defect rates, continuous evaluation)

• Supplier development including (improvement support, collaboration, capability building, partnership approach, mutual benefit)

10.2 Incoming Material Control

• Receiving inspection including (inspection upon receipt, verification, sampling, acceptance decision, controlled entry)

• Certificate verification including (certificate review, conformance checking, validity verification, acceptance, documentation filing)

• Material testing including (physical testing, chemical testing, performance testing, independent verification, quality validation)

• Supplier non-conformance including (rejection, notification, return authorization, corrective action request, supplier accountability)

• Supplier corrective action including (problem communication, root cause request, action verification, performance improvement, problem resolution)

11. Customer Quality Requirements

11.1 Customer Specifications

• Specification review including (requirement understanding, capability assessment, clarification, acceptance, mutual agreement)

• Special requirements including (customer-specific requirements, inspection points, witness points, documentation, tailored approach)

• Quality documentation including (required reports, certificates, test data, inspection records, customer deliverables)

• Customer notifications including (non-conformance notification, quality alerts, shipment notifications, transparent communication)

• Customer satisfaction including (requirement fulfillment, expectation management, feedback, relationship building, value delivery)

11.2 Quality Communication

• Quality reporting including (periodic reports, quality metrics, performance data, transparency, proactive communication)

• Issue notification including (timely communication, problem disclosure, resolution updates, transparent approach, trust building)

• Quality meetings including (regular reviews, issue discussion, improvement planning, collaborative approach, partnership)

• Customer feedback including (complaint handling, feedback analysis, improvement actions, responsiveness, customer focus)

• Continuous improvement including (joint initiatives, collaboration, shared goals, partnership approach, mutual benefit)

12. Quality Audits and Assessments

12.1 Internal Quality Audits

• Audit purpose including (compliance verification, effectiveness assessment, improvement identification, system validation, assurance)

• Audit planning including (scope definition, schedule, checklist preparation, auditor assignment, logistics, systematic approach)

• Audit execution including (opening meeting, evidence collection, observation, interview, document review, objective verification)

• Audit findings including (conformance, non-conformance, observations, improvement opportunities, objective assessment, factual reporting)

• Audit follow-up including (corrective action, verification, effectiveness check, closure, continuous improvement, accountability)

12.2 External Audits

• Customer audits including (customer assessment, facility tour, process review, documentation review, capability demonstration)

• Third-party audits including (certification audits, surveillance audits, regulatory inspections, independent assessment, objective verification)

• Audit preparation including (documentation readiness, facility preparation, personnel briefing, organized presentation, professional readiness)

• Audit response including (finding acknowledgment, corrective action planning, evidence provision, timely response, professional engagement)

• Continual improvement including (audit learning, system enhancement, capability building, ongoing development, excellence pursuit)

13. Quality Culture and Improvement

13.1 Quality Culture

• Quality awareness including (training, communication, quality importance, standards understanding, shared responsibility, mindset development)

• Employee engagement including (involvement, empowerment, suggestion systems, recognition, ownership, active participation)

• Quality mindset including (right first time, prevention focus, attention to detail, pride in work, quality consciousness)

• Continuous improvement including (Kaizen, incremental improvement, problem-solving, innovation, ongoing enhancement, never settling)

• Management commitment including (leadership, resource provision, support, expectation setting, role modeling, visible commitment)

13.2 Training and Competency

• Training needs including (skill requirements, knowledge gaps, competency development, capability building, continuous learning)

• Training programs including (induction training, on-job training, skill development, refresher training, systematic approach)

• Competency assessment including (skill verification, knowledge testing, practical demonstration, certification, capability validation)

• Training records including (training history, competency records, certification tracking, compliance documentation, evidence maintenance)

• Continuous development including (skill enhancement, knowledge updates, career development, capability improvement, professional growth)

14. Case Studies & Group Discussions

• Real-world QA/QC scenarios including (inspection challenges, non-conformance situations, supplier quality issues, manufacturing quality cases)

• The importance of proper training in developing effective QA/QC capabilities