Quality Control Course

Lesson 1 • History and Evolution of QC

Traces QC from craft inspection to modern systems thinking. Provides historical context that explains why current practices exist.

Lesson 2 • Cost of Quality Analysis

Breaks down prevention, appraisal, and failure costs using the PAF model. Enables students to justify QC investments with financial data.

Lesson 3 • Key QC Roles and Responsibilities

Maps organisational roles involved in quality assurance and control. Clarifies accountability structures students will operate within.

Lesson 4 • Defining Quality and Its Dimensions

Introduces multiple definitions of quality and key dimensions such as performance, reliability, and conformance. Anchors all subsequent QC methods in a shared conceptual framework.

Lesson 1 • Probability Concepts in Quality

Introduces probability rules, distributions, and their relevance to defect prediction. Connects statistical theory to practical inspection decisions.

Lesson 2 • Measurement System Analysis

Evaluates the accuracy, repeatability, and reproducibility of measurement systems. Ensures data collected for QC decisions is trustworthy.

Lesson 3 • Hypothesis Testing for QC

Applies t-tests, chi-square, and ANOVA to compare process outputs against specifications. Gives students tools to make statistically valid accept/reject decisions.

Lesson 4 • Descriptive Statistics for Process Data

Covers measures of central tendency, dispersion, and data distribution shape. Provides the numerical language used throughout all QC analysis.

Lesson 1 • Check Sheets and Data Collection

Designs structured check sheets for systematic defect and event recording. Establishes disciplined data collection as the foundation for all analysis.

Lesson 2 • Scatter Diagrams and Correlation

Uses scatter plots and correlation coefficients to explore variable relationships. Supports evidence-based decisions about process parameter adjustments.

Lesson 3 • Cause-and-Effect and Pareto Analysis

Applies fishbone diagrams and Pareto charts to identify and prioritise root causes. Directs improvement effort toward the highest-impact defect sources.

Lesson 4 • Stratification and Flow Charts

Applies stratification to separate data by source and flow charts to map processes. Reveals hidden variation patterns and process logic gaps.

Lesson 1 • Control Chart Interpretation Rules

Applies Western Electric and Nelson rules to detect non-random patterns. Trains students to distinguish actionable signals from random noise.

Lesson 2 • Variation and Process Stability Concepts

Distinguishes common-cause from assignable-cause variation and defines statistical control. Establishes the conceptual basis for all control chart interpretation.

Lesson 3 • Process Capability Analysis

Calculates Cp, Cpk, Pp, and Ppk indices to quantify how well a process meets specifications. Links SPC monitoring to customer requirement fulfilment.

Lesson 4 • Attributes Control Charts

Builds p, np, c, and u charts for count and proportion defect data. Extends SPC to processes where measurement is impractical or categorical.

Lesson 1 • Attribute Sampling Plans

Applies single, double, and multiple sampling plans for attribute inspection decisions. Covers plan selection using standard sampling tables.

Lesson 2 • Variables Sampling Plans

Designs sampling plans based on measured data to achieve tighter quality protection with smaller samples. Demonstrates efficiency gains over attribute plans.

Lesson 3 • Incoming and Supplier Inspection

Applies sampling and inspection methods to evaluate supplier-delivered materials. Integrates inspection results into supplier performance management.

Lesson 4 • Operating Characteristic Curves

Constructs and reads OC curves to visualise sampling plan discrimination power. Enables students to evaluate and compare plan performance objectively.

Lesson 1 • Corrective and Preventive Action

Designs CAPA systems that address root causes and prevent recurrence across the organisation. Connects problem solving to the management system.

Lesson 2 • Root Cause Analysis Methods

Applies 5-Why, fault tree analysis, and failure mode mapping to trace defects to their origins. Equips students with multiple RCA tools for different problem types.

Lesson 3 • Problem Definition and Scoping

Uses problem statements, is/is-not analysis, and impact quantification to define quality problems precisely. Prevents wasted effort on poorly scoped investigations.

Lesson 4 • Mistake-Proofing and Error Prevention

Applies poka-yoke principles to design processes that prevent or detect errors at the source. Shifts quality assurance from detection to prevention.

Lesson 1 • Internal Audit Planning and Execution

Plans, schedules, and conducts internal audits using evidence-based techniques. Develops students' ability to evaluate QMS conformance and effectiveness.

Lesson 2 • QMS Structure and Documentation

Maps the hierarchy of quality manuals, procedures, work instructions, and records. Establishes the documentation architecture that supports a functioning QMS.

Lesson 3 • Management Review and Continual Improvement

Structures management review inputs and outputs to drive QMS improvement decisions. Connects audit results and performance data to strategic quality planning.

Lesson 4 • Process Approach and Risk-Based Thinking

Applies process mapping and risk assessment to design a QMS that prevents failures proactively. Aligns QMS design with modern standards requirements.

Lesson 1 • Design for Quality and Reliability

Applies DFMEA, design reviews, and reliability testing to build quality into products before production. Prevents downstream defects through upstream design control.

Lesson 2 • Quality Performance Metrics and Dashboards

Designs KPI frameworks and visual dashboards to track quality performance across the organisation. Enables data-driven quality leadership and reporting.

Lesson 3 • Lean Quality Integration

Combines lean waste elimination with QC methods to improve process flow and reduce defect opportunity. Demonstrates synergy between lean and quality disciplines.

Lesson 4 • Supplier Quality Management Strategy

Builds supplier qualification, monitoring, and development programmes to extend QC across the supply chain. Reduces incoming quality risk at the source.