QUALITY CONTROL AND ASSURANCE FOR NEW EQUIPMENT

QUALITY CONTROL AND ASSURANCE FOR NEW EQUIPMENT

 Quality Assurance vs. Quality Control Explained

When procuring new equipment, quality assurance (QA) and quality control (QC) are essential components of a robust quality management system. QA is the proactive process of designing quality into the entire system, from procurement to production, while QC is the reactive process of inspecting and testing the product to ensure it meets quality standards.

Quality assurance for new equipment

Quality assurance activities focus on preventing defects before they occur by creating and documenting the right processes and procedures. Key QA activities for new equipment include:

Supplier evaluation: Before purchase, you must vet and monitor suppliers to ensure they can provide materials and components that meet your quality requirements.

Clear specifications: Provide clear and accurate specifications to the vendor detailing the equipment's functional, dimensional, and performance requirements.

Quality planning: Ensure the supplier has an acceptable production quality control plan and approve it before production begins. This includes specifying hold points for inspections and tests you wish to witness.

Audits and inspections: Conduct audits of the manufacturer's facility and perform pre-delivery inspections to verify that the equipment meets your standards.

Design review: Involving a cross-functional team in the design review to ensure the equipment is manufacturable, maintainable, and reliable.

Acceptance testing: Define acceptance test procedures and criteria, such as a Factory Acceptance Test (FAT) and a Site Acceptance Test (SAT), to be performed at the vendor's facility and your site.

Quality control for new equipment

Quality control focuses on identifying and correcting defects in the new equipment itself before it is fully deployed. QC activities confirm that the equipment conforms to the specifications established during the QA phase. Key QC activities include:

Component inspection: Inspect raw materials and components from suppliers to ensure they meet the required quality standards.

Functional testing: Test the finished equipment to ensure all functions operate as intended and meet performance specifications.

Production lot testing: For equipment that is part of a larger production batch, test a random sample to validate its quality conformance before acceptance.

Visual and dimensional inspection: Visually inspect the equipment for any cosmetic defects and perform precise dimensional checks to ensure it conforms to the technical drawings.

Software and system testing: If the new equipment contains software, perform rigorous testing to check for defects, glitches, or other functional issues.

Implementation and best practices

For a successful equipment rollout, integrate QA and QC into a comprehensive quality management system (QMS).

Establish a QMS: Create a quality management system that defines the processes, procedures, and responsibilities for ensuring consistent quality.

Create a robust feedback loop: Use data from QC inspections to inform QA processes. When defects are found, investigate the root cause and implement corrective actions to prevent recurrence.

Ensure proper training: All personnel involved with the new equipment, from procurement to operation, must be trained on the established quality standards and procedures.

Embrace digitization: Use computer-aided quality control and quality assurance (CAQC/CAQA) software to automate data collection, improve accuracy, and streamline real-time monitoring of quality parameters.

Automate inspections and audits: Automate inspection checklists and data collection to reduce human error and ensure consistent application of quality standards