9.

Quality Control
Table of contents
Table of contents..........................................................................................................................................1 9.1 Organizational Structure- Quality assurance..........................................................................................2 9.1.1 Product Realization.........................................................................................................................2 9.1.2 Testing............................................................................................................................................2 9.1.3 Validation........................................................................................................................................2 9.1.4 Process Engineering........................................................................................................................3 9.1.5 Analysis/Method.............................................................................................................................3 9.2 Statistical Quality Control......................................................................................................................4 9.3 Routine setup for inspection at HBL......................................................................................................4 9.3.1 Briquetting/ powder filling..............................................................................................................4 9.3.2 Ball rolling......................................................................................................................................5 9.3.3 Plate blank shearing:.......................................................................................................................5 9.3.4 Formation:......................................................................................................................................6 9.3.5 Inward inspections..........................................................................................................................7 9.4 Instruments for inspection and their calibration.....................................................................................8 Conclusion.................................................................................................................................................10

9.1 Organizational Structure- Quality assurance

The Quality control of QA/QC is completely different from the rest of the production line managers and their organizational hierarchy. The HOD is directly responsible to the director as the quality is the key for the success of any organization. The customer is the king for any organization in which ever field we go. Thus the HOD is completely responsible and takes charge of the Quality assurance. The organizational structure is given in below with explanation of each one of them.

9.1.1 Product Realization

The group is divided in further groups: 1. The in-ward goods inspection and 2. The In-process inspection 9.1.1.1 In - Ward Goods inspection Inspection activity that involves inspection of in-ward Raw material and Components, Corrective and preventive action followup form supplier, Supplier wise inspection data analysis and supplier rating, Documentation related to in-ward. 9.1.1.2 In - process inspection Inspection activity is carry out at each process stage as per the process specifications, Inspection data analysis, Conducting monthly shop floor meetings, Creating Quality Circles to eliminate the rejections, Monitoring the efficiency of the Corrective actions and process.

9.1.2 Testing
The testing of batteries is done in various stages in different departments. It divided into 2 groups: 9.1.2.1 Final Testing, Customer Inspection, Packing Inspection activity is carried out on finished product as per the check list & process specifications. The Customer inspects as per the standards and Monitoring the Packing and Dispatch activities. The customers in some cases come to perform the inspection and audits. 9.1.2.2 Calibration Calibration is to carry out the calibration activities for instruments, gauges & MMEs by using in-house or out sourcing facilities. The function of this department is Monitoring & Maintain calibration master list, Calibration Verification register, not in use instruments list, Identification purpose & Out of use instruments list.

9.1.3 Validation
9.1.3.1 First Article Inspection (F.A.I) FAI is the objective evidence that the process being capable of manufacturing conforming product before additional product is manufactured with the process being monitored. FAI is carried for following cases i.e The first time material provide, A change in design, a change in manufacturing source, a new product/Design Development & After major maintenance of machine / Equipment. 9.1.3.2 Special Processes validation The process where the resulting output cannot be verified by subsequent monitoring and measurement, the process deficiencies may only become apparent after an intermediate component is further processed or finished product is in use.

9.1.3.3 Supplier Evaluation /validation Validation process shall monitor and ensure the outsourcing product / process. Feasibility study & risk analysis shall be conducted with respect to supplier.

9.1.4 Process Engineering

This department focuses on the design, operation, control, and optimization of processes through the aid of systematic methods. Lead improvements to product quality through manufacturing processes enhancement and continually seek to drive improvements in process design, manufacturing layout and operational performance

9.1.5 Analysis/Method
9.1.5.1 Monitoring, measurement, analysis and improvement Monitoring & measurement of customer satisfaction, processes, product, COPQ, Replacements cost, knowledge up gradation (on job training) & KPIs and internal audits. 9.1.5.2 Control of Non conformities Identify process non conformities - Root cause analysis using QC tools- Detecting potential causes for process failure and its occurrence severity - CAPA to eliminate / minimize. 9.1.5.3 Improvements Productivity improvement - Quality improvement - Improvements through Knowledge management, customer relationship management, Control of production process changes, cost management, Change management & Obsolescence management.

Figure 1: The organization structure of QC dept

9.2 Statistical Quality Control

Statistica1 quality control (SQC) is the term used to describe the set of statistical tools used by quality professionals. Statistical process control (SPC) involves inspecting a random sample of the output from a process and deciding whether the process is producing products with characteristics that fall within a predetermined range. SPC answers the question of whether the process is functioning properly or not.

9.3 Routine setup for inspection at HBL

The main processes used in this division are discussed here:

9.3.1 Briquetting/ powder filling

a. briquetting briquetting is the process of compacting active material in to tablets of rectangular shape called briquettes which are encapsulated in the perforated steel strips to form the hose. b. Input: a. positive active material b. negative active material c. positive perforated strip d. negative perforated strip e. terphane tape c. Equipment used: a. spool feeder for strip feeding device b. briquetting m/c c. hose joining mill d. portable spot welding m/c for strip joining d. Instruments for inspection: a. electronic weighing machine b. Vernier calipers e. frequency of checking: weigh the briquettes in the weighing m/c , adjust the weight accordingly. To internal production plan. The weighing shall be done every half an hour to obtain the correct briquettes weight. f. Inspection: visual inspection of the hoses: the rolling of the strip together to form hoses os to be done carefully, open hose is not to be used, there should not any visible crack on the strip, no flaking, corroded strips are not to be used.

9.3.2 Ball rolling

a. description: ball rolling is the process of joining hoses together to form carpets. This instruction relates to the positive and negative plate blanks rolled in loping lengths called positive and negative carpets. Inputs: a. Hoses b. ball rolling m/c instruments used: a. Vernier calipers b. feeler gauge c. spanner d. mirror b. Inspection: Dimensions of the carpets are to be maintained as per specifications (carpets width and carpet thickness) given in documenting and joining of the pockets must be satisfactory. All necessary adjustments are to be made on the ball mill for taking out the plate blanks according to the specifications. Initially one or two small carpets are produced and checked. The inspector shall give clearance when the plate blank are produced according to the specification. There after the machine operator is responsible for the maintaining the dimension according to the specification. Record the reading in the first piece inspection report, document for first piece inspection report.

9.3.3 Plate blank shearing:

Description: Plate blank shearing is the process of shearing the plate blanks produced in long length to the required dimensions for making the plates. This instruction relates to the positive and negative plate blanks, which are cut into the required size. Inputs: Carpets- the operator shall verify that the plate blank carpets given to him are as per description (thickness and number of pockets) in the job card. Equipment: Shearing machine Instruments: a. Vernier caliper b. try square c. feeler gauge.

Inspection: Check the first piece using the Vernier and one piece in every carpet particularly for perpendicularity using a try square. Also check for width and burr. If found defective, stop the machine, change the setting and rectify before proceeding further record the reading in the first piece inspection report document for the first piece inspection report. The QA inspector shall inspect the plates 100% for visual defects and the lots for dimensions (as per IS02500).

9.3.4 Formation:
Description: Formation is the process of activating the stacks by charging and discharging with specific currents. Electrolyte (potassium hydroxide solution) being act as a medium for the exchange of the positive and negative ions during charging and discharging. Inputs: a. Electrolyte/ stacks / ICC s b. Copper cable 120mm*150mm c. PP / FRP formation tanks d. SFM / PP / UPVC containers e. Rails / nut and bolts. Equipments: a. Chargers cum dis chargers b. resistance coils c. multimeter d. clamp meter e. Thermometer f. Hydrometer

g. water spray nozzles h. analog type pressure gauges i. j. pneumatic guns AODD pumps

k. gantry Process Instructions: the process instructions involving the following sub stages: stage1: selection of the container stage2: Assembling of raw stacks

stage3: electrolyte filling stage4: soaking of the stacks stage5: activation stage Inspection: Operation has to inspect visual defects like free of the pocket damage, lip burst, plating peel off threading damage & low voltage. Generally when the batteries are reached to this stage, it is highly unlike that any rejection will be there. The major rejection is not in this stage. It happens in the preliminary stages.

9.3.5 Inward inspections

Almost all the components are been verified batch wise. From the tab been used till the active material, all are certified. The main components of the R & D test report are given below: CHP Report The active material used is tested in the IMA Lab where the following parameters are been validated. The specification of negative material (cadmium hydroxide) which are generally accepted for the production line are given. S. no. 1 2 3 Parameters Appearance Tap density Sieve Analysis (+) 1.68 mm (ASTM mesh#12) Min 85% Specification

to (+) 0.106mm(ASTM mesh Max 15% #140) 4 Chemical Composition a. Moisture(H2O) b. Cadmium (Cd) c. Nickel 5 Efficiency of mono-cell at 0.2C discharge at 1.0 discharge Min 260 Ah/Kg Min 220 Ah/Kg 1-3% 75-78% 3-5%

NHP Report The active material used is tested in the IMA Lab where the following parameters are been validated. The specification of negative material (Nickel Hydroxide) which are generally accepted for the production line are given.

S. no 1

Parameters Chemical Composition a. moisture b. Graphite c. Nickel d. Sulphates e. carbonates

Specification

6-8% 18.5-20.5% 42-465 Mx. 1.30% Max0.5% 1.15-1.30gm/cc

2 3

Tap density Sieve Analysis

(+) 0.425 mm (ASTM mesh# 40) Min 85% (-) 0.425mm (ASTM mesh #40) 4 Efficiency of Mono-cell efficiency at 0.2C discharge efficiency at 1.0C discharge . Min 190 Ah/Kg Min 150Ah/Kg Max 15%

9.4 Instruments for inspection and their calibration

The following instruments are used for the inspection at various stages. The measuring instruments are compared with the standard instruments and then the variation is calculated. This process is called calibration. The instruments are calibrated at a certain period of time based on the variation of the errors. The variation of errors is calculated for periodic time and then the fixed time for which the instrument needs to be calibrated is decided accordingly. Since the instrument is regularly calibrated, the percentage of the errors is very less. The standard instruments used with their working range/ dimensional accuracy, where it gives the accurate results.

S. no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

instrument/gauge weighing machine Hydrometer vernier caliper pressure gauge digital weighing machine digital voltmeter spring balance torque wrench clamp meter Multimeter digital ammeter Shunt Ammeter Thermometer temperature gauges conductivity meter Tds meter digital EC meter digital pH meter digital timer digital temperature controller True rms multimeter thread plug gauge thread ring gauge dial Vernier height gauge

department stores/briquetting/lab stores/formation/chemical plant/lab briquetting/Q.A shearing/briquetting/projection welding/chemical plant/cell assembly briquetting/Q.A/lab/chemical plant formation CAL Lab Plate block assembly formation formation formation formation formation formation/ chemical plant formation formation/ chemical plant formation/ chemical plant formation/ chemical plant formation/ chemical plant cell assembly cell assembly cell assembly Q. A Q. A Q. A Q. A

Dimensional accuracy 1-90Kgs 20-35 C 0-300mm 0-300Kg/cm 0-3Kgs 195-300V 0-10Kgs 12-60Nm 0-300A 10V 0-150A 0-150A 300A 30-100 C 20-100 C 0-30 us/cm 20PPM 0-30 us/cm 5-9 pH 4-8 sec 295-315 C 0-10V NA NA 0-200mm 0-300mm

Conclusion
Thus in this assignment we have brought down the organization structure of Quality assurance/ Quality control department. Then we brought in the light the routine setup involved in the organization, with the regular tests in R&D and also the gauges and the measuring instruments with their dimensional accuracy, the least count of all the instruments were not available. Most of the inspection done is visual inspection and sometimes physical. The brief about Statistical process control is explained.