In today's landscape, a good quality control plan is a must for companies, regardless of their industry. Customers demand high-quality products and services, governments have strict national laws, and international regulations (such as ISO 9001, the gold standard for quality) have become the norm. Top-notch quality control (QC) is extremely important.
Quality control helps businesses maintain safety in the workplace, produce consistent products and services, and meet customer demands, all while avoiding legal fines and penalties. It requires proper training, having clear benchmarks, and regular testing and monitoring. This is where quality control plans come in.
Thorough documentation and guidelines make it easier for your organization and employees to have a structured framework for QC. This quality plan must outline key practices, activities, and more. In this article, we will discuss what a QC plan is, how to create one, and best practices.
What is a Quality Control Plan?
QC plans refer to documentation outlining the necessary criteria and processes required for a project to meet standards. It typically includes instructions on planning, managing, and controlling QC levels in the department, project, or organization. It plays a central role in most organizations' processes and ensures that any waste and costs are reduced.
It is essential to remember that while some QC practices may be universal, most depend on your industry. For example, food production companies will have very different protocols and quality standards than clothing manufacturers or aerospace production plants. When creating a control plan, it is essential to consider the industry you are in and include practices like automation, computerized tracking, and more.
Why is a Quality Control Plan Important?
Quality management is one of the most basic requirements for any company today. Here are some reasons why it is necessary:
- Minimizes the chances of defects and errors, allowing organizations to meet deadlines and customer expectations better.
- Reduces costs by focusing only on what is absolutely necessary for the project to be completed.
- Ensures business processes and activities are carried out smoothly by outlining what employees are expected to do.
- Allows stakeholders and other executives to monitor an organization's or project's progress by outlining the objective, success metrics, and more.
How To Create a Quality Control Plan
1. Establish Clear Objectives
The first step to any good quality control plan is clearly understanding your objectives. This could vary depending on your brand, target audience, and industry. Product design, specifications, and quality will define your goals in this step. For example, the materials required to make your product, what it should be able to do, design, and what standards it needs to meet.
For example, if your product is plastic plates, you must specify all relevant information, such as the diameter must be 10 inches, the thickness be 0.5 inches, the height be 1 inch, and the color must be navy blue. The plate might have to be made of a specific type of plastic that is safe to serve foods on, non-toxic, and microwavable.
The more detailed the objectives and specifications, the easier for manufacturers to follow them. Similarly, clear goals and instructions for other departments will help employees understand what they must do.
2. Lay Out Steps, Practices, and Procedures
Once your objectives have been clearly defined, it is time to document the procedures, protocols, and steps required to maintain quality. This portion of the plan must also cover the protocol if the inspection uncovers problems. To put it simply, any necessary plans to maintain quality at any step of the process must be included here. This could include the following:
- Selecting quality materials
- Outlining the standards of execution
- Regularly monitoring and testing the project or product at different stages
- Documenting each aspect to maintain transparency and accountability
3. Assign Roles and Responsibilities
After outlining the steps for QC, organizations must assign tasks to employees. Assigning responsibilities is crucial to ensure all employees can do their work effectively. This includes assigning who will monitor quality at all stages and appointing quality-control inspectors, on-site managers, subcontractors, etc.
4. Provide Quality Control Training
Employee training is critical to effective quality control and management. It helps employees understand quality management procedures and their role in maintaining them. Depending on your organization's requirements, training could include quality control plans, the importance of maintaining quality standards, specific skills an employee may need, and more. Training must also be a continuous process to update team members on any changes, keep them up-to-date on all regulatory and compliance requirements, and ensure new hires are also in the loop.
5. Conduct Inspections, Product Testing, and Audits
This is another critical step in the quality management process. Regular inspections, product testing, and audits can help identify issues early on. Addressing them early on ensures the final product meets the quality standards outlined earlier in the document. It is also vital to document inspections and audits.
6. Evaluate Success and Be Flexible
The final stage of your QC plan includes regular reviews of audits, inspections, and resting reports. Tracking these trends over time can help identify areas for improvement. This part of your plan should also include what determines success or failure. It is also important that your quality control plan is flexible and accommodates any updates in your procedures or quality standard requirements.
Quality Control Best Practises
1. Be Thorough
Quality control plans must include comprehensive guidelines regarding your company's goals, quality standards, desired results, procedures, tools, and other general criteria.
2. Use Automation
Many quality management (QMS) systems offer one vital tool—automation. Automating tasks is a simple way to ensure your company can adhere to predefined procedures and protocols. This also enhances consistency, speed, and efficiency. Automation ensures fewer human errors, increases accuracy, and can be integrated into documentation. Removing human labor can also lead to fewer accidents and reduce costs.
3. Use Computerized Tracking
Good QMS software can also track your processes, including supplies, manufacturing, shipping, customer support, and experience. The information documented from tracking could be used to assess the performance of your suppliers, monitor quality problems, improve customer experience, and identify patterns.
4. Have Regular Reviews and Audits
Regular internal and external audits can confirm that quality standards are being met. It can also identify problems in your workflow, which can be addressed to improve procedures.
To Conclude
Quality control plans can be a critical factor in determining the success of your organization. However, creating and sticking to a quality control plan can be challenging. Luckily, several tools are available to make the process easier.
If you are looking for state-of-the-art QMS software, consider Effivity. We offer process documentation, audit modules to ensure you remain audit-ready at all times, employee training modules, design and development modules, and more. To learn more, head to Effivity's website today!
