Chapter 2: Quality Management Systems (QMS)

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🔍 2.1 What is a Quality Management System (QMS)?

A QMS is a structured system of policies, procedures, and processes required for planning and execution in core business areas to improve quality and meet customer requirements.

🔧 In mechanical industries, a QMS helps ensure that fabricated, machined, or assembled products meet defined quality standards consistently.

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🧩 2.2 Key Objectives of QMS

Ensure customer satisfaction

Standardize processes to reduce variability
Prevent non-conformities (defects)
Facilitate continuous improvement
Comply with ISO 9001 and other industry-specific standards

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📜 2.3 ISO 9001: The Backbone of QMS

🌍 ISO 9001:2015 – International Standard for QMS

🧱 Core Structure:

Clause 1 – Scope

Clause 2 – Normative References
Clause 3 – Terms and Definitions
Clause 4 – Context of the Organization
Clause 5 – Leadership
Clause 6 – Planning
Clause 7 – Support
Clause 8 – Operation (Product/Service Realization)
Clause 9 – Performance Evaluation
Clause 10 – Improvement

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🔄 2.4 The PDCA Cycle: Heart of QMS

Phase	Description	Example in Industry
Plan	Define objectives, identify risks	Plan welding sequence and ITP
Do	Implement processes	Weld components as per WPS
Check	Monitor and measure performance	QC inspector checks welds using NDT
Act	Take action on findings, improve processes	Corrective action if defects found

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📂 2.5 Key Documents in QMS (with Field Examples)

Document Type	Description	Industrial Example
Quality Manual	Overview of the company’s QMS	Policies, responsibilities, flow charts
SOP (Standard Operating Procedure)	Step-by-step process instructions	Welding SOP, Inspection SOP
Work Instruction	Specific task guidelines	"How to calibrate micrometer"
Quality Policy	Management’s commitment to quality	Signed by GM/Director
Record	Evidence of activities performed	NDT Report, Welder Qualification Record

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🧪 2.6 Process Control and Product Control

Control Type	Focus	Example
Process Control	Quality of the method	Ensuring preheating temperature in welding
Product Control	Quality of the result	Dimensional check of finished flange

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🧰 2.7 Real-World Industrial Example: QMS in Action

🏭 Industry: Heavy Fabrication (Pressure Vessels)

Scenario:
Client demands ASME-compliant pressure vessels.
The fabrication shop follows QMS:

✅ SOP for receiving raw material
✅ MTCs verified & recorded
✅ Welders trained and qualified as per WPS
✅ In-process inspections logged in checklists
✅ NDT carried out and reports submitted
✅ Final inspection with client representative
✅ Documentation archived as per ISO 9001

📌 Outcome: No defects reported, zero rejection, high client satisfaction.

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🔧 2.8 How Mechanical Engineers Use QMS in the Field

1. Daily Use of Checklists & SOPs

2. Maintaining Calibration Records

3. Filling Inspection Reports

4. Participating in Internal Audits

5. Reviewing Vendor Quality Documents

6. Ensuring Documentation for Compliance

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🧠 Summary

QMS ensures consistent, repeatable quality processes.

ISO 9001 is the global standard for QMS.
PDCA cycle helps drive continuous improvement.
Mechanical engineers use QMS to manage fabrication, inspection, testing, and reporting.

Quiz: Quality Management Systems (QMS)

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Q1. What does QMS stand for?
A) Quality Material Standard
B) Quality Management System
C) Qualified Measurement Standards
D) Quick Manufacturing Setup
🟩 Correct Answer: B

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Q2. Which international standard defines requirements for QMS?
A) ASME Section IX
B) ISO 14001
C) ISO 9001
D) API 650
🟩 Correct Answer: C

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Q3. Which of the following is a process-focused control method?
A) Final product testing
B) Dimensional inspection
C) In-process welding temperature check
D) Visual inspection after painting
🟩 Correct Answer: C

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Q4. The PDCA Cycle used in QMS stands for:
A) Plan-Do-Check-Act
B) Process-Design-Control-Audit
C) Plan-Deliver-Control-Approve
D) Produce-Deliver-Check-Arrange
🟩 Correct Answer: A

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Q5. What is the purpose of a Quality Manual?
A) To list all product dimensions
B) To provide machine operating instructions
C) To describe the overall QMS structure and policy
D) To calibrate measuring tools
🟩 Correct Answer: C

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Q6. Which of the following documents is used for detailed step-by-step task execution?
A) Quality Policy
B) Work Instruction
C) Quality Manual
D) Audit Report
🟩 Correct Answer: B

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Q7. What type of control is used when recording MTCs and verifying heat numbers?
A) Product Control
B) Design Control
C) Calibration Control
D) Leadership Control
🟩 Correct Answer: A

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Q8. Why is a QMS important in mechanical fabrication?
A) It increases welding speed
B) It allows bypassing inspections
C) It ensures consistent quality and customer satisfaction
D) It reduces manpower
🟩 Correct Answer: C

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Q9. In which clause of ISO 9001 is “Leadership” covered?
A) Clause 4
B) Clause 5
C) Clause 6
D) Clause 8
🟩 Correct Answer: B

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Q10. Which principle promotes continual improvement in ISO 9001?
A) Do More With Less
B) Fit for Purpose
C) PDCA Cycle
D) Chain of Command
🟩 Correct Answer: C