Lesson video

Hello there.

My name's Mrs. Taylor, and I'm really pleased you can be here to join me for our lesson today.

Our lesson today is "Quality" and this is part of the "Designing and Making Principles" unit.

The outcome.

I can explain how products are monitored and tested to meet quality standards.

We have four keywords.

Quality Assurance, which is abbreviated to QA, which is ensuring the production process prevents mistakes and maintains quality.

Quality Control, which is abbreviated to QC.

These are the checks made on a product before, during, and after its production so it meets quality and safety standards.

Tolerance.

The acceptable range of variation in a product's dimensions or weight.

And standardise.

Make components or processes the same to ensure consistency and quality.

The lesson has two parts.

Quality Assurance, or QA, and Quality Control, or QC.

Let's get started.

Imagine a factory making thousands of smartphones every day.

Some phones leave the factory with faulty screens or batteries that overheat.

What could the company do to prevent these defects before the phones are made? Laura says, "They could check each phone for faults before it leaves the factory." And Sam says, "Wouldn't it be better to prevent defects rather than fix them later?" What do you think? Quality Assurance are the steps taken to ensure that the production process itself prevents mistakes and maintains consistent quality in the final product.

Quality Assurance is about making sure manufacture runs smoothly and avoiding defects from the start.

Here we can see a production line in the photograph.

Quality Assurance helps maintain high standards of production performance.

Let's have a check for understanding.

True or false? Quality Assurance only checks products for quality.

Pause the video and have a go.

Great.

Let's check.

That's right.

It's false.

Because Quality Assurance focuses on preventing defects by improving the production process.

Well done.

Quality Assurance involves standardising production methods to ensure products are made to the correct specifications.

Standardising is making sure that everything is done in exactly the same way.

Standardising can include programming machinery to do the same task, training workers on manufacturing techniques, regular machinery maintenance, and using standardised components.

Standardised components are pre-made parts that are identical in size, shape, and function.

Examples include electronic components, such as motors, LEDs, resistors, and USB ports.

Mechanical fixings, such as zips, screws, nuts and bolts, or hinges.

Gear wheels are also examples of standardised components.

Standardised components support Quality Assurance by consistency.

Reducing the variation and the parts are of high-quality.

Faster production.

Less time checking, and easier to assemble.

Fewer defects.

The parts are already tested and there are minimal errors.

And easier quality checks.

Simplified inspections, and extra checks are not needed.

Here we have another check for understanding.

Why is it important to have a standardised production process as part of Quality Assurance? Is it A, to reduce the cost of materials? B, to make the process quicker? C, to ensure consistent quality and prevent mistakes? Or D, to increase product variation? Pause the video and have a go.

Great.

Let's check.

That's right.

It's C.

To ensure consistent quality and prevent mistakes.

Well done.

By using standardised components and methods, Quality Assurance ensures that each product is made the same way, reducing the chance of errors.

This helps to maintain consistent quality, ensuring products meet the desired performance and safety standards.

Quality Assurance techniques can be applied to a wide range of products.

Here we can see a production line for some baked goods.

Using an example of a smartphone, a manufacturer could standardise how the screen is attached.

The equipment.

We could use the same machines or robots to reduce human error.

The process.

Clean, apply adhesive, use jigs to position correctly.

And the components.

The adhesives and screws are already standardised.

Here we have your first task.

Task A.

Explain how Quality Assurance can improve a product's quality and prevent defects in the production process.

Your answer should mention what Quality Assurance is, the importance of standardising production, and an example of how this might be done in industry.

Pause the video.

Have a go.

Great.

Let's have a look at some of the answers you may have come up with.

Quality Assurance improves a product's quality by focusing on preventing defects before they happen.

Instead of just checking finished products, Quality Assurance ensures that the entire production process is designed to maintain high standards.

One way Quality Assurance does this is by standardising production.

This means using consistent methods, materials, and components so that every product is made the same way.

When a company standardises its processes, it reduces mistakes, improves efficiency, and ensures every product meets the same quality level.

For example, a phone manufacturer might standardise how screens are attached to phones.

By following the same steps every time, workers are less likely to make errors and every phone will have a securely-fitted screen.

Well done.

We now move to the second part of our lesson, which is Quality Control.

Quality Control refers to the process of checking and testing products before, during, and after production to ensure they meet quality and safety standards.

Unlike Quality Assurance, which focuses on preventing mistakes, Quality Control identifies defects in finished or semi-finished products.

Sam says, "Quality Control is part of the Quality Assurance process, but focuses on the product only." Let's have a check for understanding.

Why is Quality Control important? Is it A, it helps identify and correct defects in products? B, it speeds up the production process? C, it removes the need for standardisation? Or D, it allows more defective products to be sold? Pause the video and have a go.

Wonderful.

Let's check.

That's right.

It's A.

It helps identify and correct defects in products.

Well done.

As no two products are exactly the same, there needs to be a tolerance within Quality Control checks.

A tolerance is the acceptable range of variation in a product's dimensions or weight.

It is shown as a number with a plus-minus sign in front of it, and the plus-minus sign is used to show a range of possible values.

For example, when a tolerance of plus-minus 0.

1 millimetres is applied to a five-millimeter dimension, the acceptable size is between 4.

9 millimetres and 5.

1 millimetres.

If a product is outside the acceptable tolerance, it may not function properly and will fail quality checks.

Quality Control ensures only products within the set tolerance range reach customers.

A skateboard truck axle is designed to be eight millimetres, with a plus-minus of 0.

05 millimetres in diameter.

It can therefore be between 7.

95 millimetres and 8.

05 millimetres and still be within tolerance.

If the axle is too thick, the wheel bearings won't fit.

If the axle is too thin, the wheels might fall off.

This is why skateboard parts are made with tight tolerances to ensure a smooth and safe ride.

Let's have another check.

A company makes phone screens that must be five-millimeters thick, with a tolerance of plus-minus 0.

1 millimetre.

Which of these screens would fail QC checks? Is it A, 4.

9 millimetres? B, 5.

1 millimetres? C, 5.

2 millimetres? Or D, 5.

0 millimetres? Pause the video.

Great.

Let's check.

That's right.

It's C.

5.

2 millimetres would be outside the tolerance and would fail the Quality Control checks.

Well done.

Quality Control involves inspecting and testing products to ensure they meet the correct specifications.

If a product does not meet the required tolerance, it may be rejected or reworked.

Common Quality Control checks include visual inspections, measuring components against standardised dimensions, and testing product performance.

Digital callipers, sometimes known as a vernier gauge, are a precise measuring tool which can be used to check parts against technical specifications.

They can be both digital, as in this example, and analogue.

Quality Control checks are made on a product before, during, and after its production.

Using the top pictured on the right, here are different types of checks that could be made at any stage of its production.

Before production.

The incoming quality checks on raw materials.

For example, inspecting fabric, threads, and dyes.

During production.

Testing at certain points to catch defects early.

For example, checking stitching and colour consistency.

And after production.

Final checks on products before they are shipped.

For example, ensuring proper sizing.

If a product fails Quality Control checks, it may be reworked, which is fixed so it meets the required standard.

Rejected, discarded if it cannot be fixed.

In some cases, products that fail Quality Control checks because of slight imperfections can be sold onto the public at a discounted price.

The benefits of this are materials aren't wasted and consumers save money.

Some consumers don't mind a product having minor flaws if it means getting higher-priced items at a lower cost.

Let's have a check for understanding.

What happens if a product does not meet the required tolerance during Quality Control checks? Is it A, it is always thrown away? Or B, it is ignored, and production continues? Or C, it is immediately sent to the customer? Or D, it may be reworked, rejected, or sold at a discount? Pause the video.

Wonderful.

Let's check.

That's right.

It's D.

It may be reworked, rejected, or sold at a discount.

Well done.

Now we have Task B.

Part one.

Explain why Quality Control is important in manufacturing.

Include the following in your answer.

How Quality Control helps identify and correct defects, the role of standardisation in ensuring consistency, and the importance of tolerance in product quality.

Part two.

The image on the right shows a stainless steel flask, designed to keep liquids hot for a long period of time.

Give examples of specific Quality Control checks to ensure that the flask is durable, leak-proof, and safe for use.

Pause the video.

Great.

Let's have a look at some of the answers you may have come up with.

For part one, Quality Control ensures products meet quality and safety standards by identifying defects before, during, and after production.

This prevents faulty items from being sold and reduces waste.

Standardisation helps maintain consistency, making it easier to produce reliable products that function correctly.

Quality Control also ensures products stay within required tolerance limits.

For example, a 10-millimeter plus or minus 0.

2-millimeter rod must fit correctly in an assembly.

Without Quality Control, defective products could lead to complaints, recalls, and safety risks.

Ultimately, Quality Control is essential for maintaining customer trust and ensuring companies produce high-quality, reliable goods.

And part two.

Material inspection.

Check the stainless steel for defects such as scratches or dents.

Leaks.

Fill the flask with water to ensure the lid and seals are watertight.

Dimensions.

Measure the flask's dimensions to ensure it meets the design specifications and will fit correctly with its lid and insulation components.

Insulation.

Check that the flask maintains the correct temperature for hot liquids over a set period.

And safety.

Inspect for sharp edges, rough surfaces that could cause injury or discomfort to the user.

Well done.

Here is a summary of our learning today.

Quality Assurance prevents defects by improving the production process.

Standardising production ensures consistency and reduces errors.

Quality Control checks products to identify and fix defects.

Standardised components help meet tolerance limits and improve quality.

Well done! And thank you for joining me today.