Task 1 (P8)
Acceptance sampling is a way of determining whether a batch
of parts produced should be accepted or rejected based on a sample of the total
parts made. If a proportion of the parts produced are outside of the minimum or
maximum limits of measurement the batch will be rejected. Advantages are it
reduces the costs for inspection, less skilled workers are required, when a
correct sample size is used it is very accurate. Disadvantages are it isn’t
fully reliable which means there is a chance of some parts being incorrect sent
to the customer and an incorrect sample size means there is a chance that some
batches of parts are not sent to the customer which aren’t all incorrect sizes.
100% inspection is where every single part produced is
checked to see if it is inside the minimum and maximum tolerances. Advantages
are it means every part sent to the customer is correct. Disadvantages are it
is time consuming, expensive and requires a large skilled workforce.
Acceptance sampling would be used if there were too many
parts to use 100% inspection as it would take too much time to measure them
all, or it would also be used when the parts produced do not have to be very
accurate as 100% inspection would take lots of time that could be used for
other purposes but means every part is made to specification and are correct
I would choose 100% inspection to measure the limits and
tolerances on the hexagonal boss because the difference between the minimum and
maximum tolerances is very small, so the part needs to be made accurately and
it means that every part sent to the customer are to specification.
Task 2 (M3)
is a bar graph that is plotted with the bars decreasing in value from left to
right along the x axis. They analyse problems (e.g. Customer complaints) and it
slows which problems need to be addressed first. It is used to increase the
quality of production of the part and efficiency by highlighting the problems
when producing the part which can then be rectified so production is faster and
This is a graph that is used to visualise data and the graph
then shows trends for example it shows where components not correct according to
specifications come from. This then improves efficiency and quality because the
machines the defective parts come from can be re calibrated and this means parts
do not have to be redone which saves time.
These are used to monitor systems and track data. This is used
to get information for acceptance sampling or 100% inspection. This improves efficiency
and quality because this gives you information about sample sizes which ensures
they are the correct size and correct method of inspection.
Control charts are line graphs with the average size of the
part, the size it should be and the maximum and minimum size the part can be. This
shows if parts are made too small or too big, so the machine can be recalibrated
or cutting tools replaced. This improves quality and efficiency because less
parts will have to be re made, because it can easily be spotted when the machine
isn’t functioning properly.
Flow charts are sets of
instructions and procedures for employees so that everything is done the same
and every employee would reject samples that are outside of the tolerance. This
improves quality and efficiency because it means if parts are rejected the next
step could be check machines accuracy and then remaking the part, which means
the next parts made should be inside tolerance saving money and time and these
parts would have a higher quality.
These are used to find the cause of problems in
the process of manufacturing the part which affect the quality. This means the
problems can be seen easily and then rectified therefore increasing the quality
of the parts produced.