Using Industrial Hydraulics |
Applications of Computer-Aided Manufacturing
Quality control engineers plan and direct procedures and activities that will ensure the quality of materials and goods. They select the best techniques for a specific process or method, determine the level of quality needed, and take the necessary action to maintain or improve quality performance. Quality control technicians assist quality control engineers in devising quality control procedures and methods, implement quality control techniques, test and inspect products during different phases of production, and compile and evaluate statistical data to monitor quality levels.
Quality control technology is an out growth of the industrial revolution, which began in England in the 18th century. Each person involved in the manufacturing process was responsible for a particular part of the process. The worker’s responsibility was further specialized by the introduction of manufacturing with interchangeable parts in the late 18th and early 19th centuries. In a manufacturing process using this technique, a worker concentrated on making just one component, while other workers concentrated on creating other components. Such specialization led to increased production efficiency, especially as manufacturing processes.
Quality control engineers are responsible for ensuring that all incoming materials used in a finished product meet required standards and that all instruments and automated equipment used to test and monitor parts during production perform properly. They supervise and direct workers involved in assuring quality, including quality control technicians, inspectors, and related production personnel.
Quality control technicians work with quality control engineers in designing, implementing, and maintaining quality systems. They test and inspect materials and products during all phases of production in order to ensure that they meet specified levels of quality. They may test random samples of products or monitor production workers and automated equipment that inspect products during manufacturing. Using engineering blueprints, drawings, and specifications, they measure and inspect parts for dimensions, performance, and mechanical, electrical, and chemical properties. They establish tolerances, or acceptable deviations from engineering specifications, and they direct manufacturing personnel in identifying rejects and items that need to be reworked. They monitor production processes to ensure that machinery and equipment are working properly and are set to established specifications.
Quality control technicians also record and evaluate test data. Using statistical quality control procedures, technicians prepare charts and write summaries about how well a product conforms to existing standards. Most importantly, they offer suggestions to quality control engineers on how to modify existing quality standards and manufacturing procedures. This helps to achieve the optimum product quality from existing or proposed new equipment.
Quality control technicians may specialize in any of the following areas: product design, incoming materials, process control, product evaluation, inventory control, product reliability, research and development, and administrative applications. Nearly all industries employ quality control technicians.
To prepare for this career, take high school classes in mathematics (including algebra, geometry, and statistics), physical sciences, physics, and chemistry. You should also take shop, mechanical drawing, and computer courses. In addition, you should take English courses that develop your reading skills, your ability to write well-organized reports with a logical development of ideas, and your ability to speak comfortably and effectively in front of a group.
Quality control engineers generally have a bachelor’s degree in engineering. Many quality control engineers receive degrees in industrial or manufacturing engineering. Some receive degrees in metallurgical, mechanical, electrical, chemical engineering, or business administration, depending on where they plan to work. College engineering programs vary based on the type of engineering program. Most programs take four to five years to complete and include courses in mathematics, physics, and chemistry. Other useful courses include statistics, logistics, business management, and technical writing.
Educational requirements for quality control technicians vary by industry. Most employers of quality control technicians prefer to hire applicants who have received some specialized training. A small number of positions for technicians require a bachelor of arts or science degree. In most cases, though, completion of a two-year technical program is sufficient. Students enrolled in such a program at a community college or technical school take courses in the physical sciences, mathematics, materials control, materials testing, and engineering-related subjects.
Certification or Licensing
Although there are no licensing or certification requirements designed specifically for quality control engineers or technicians, some need to meet special requirements that apply only within the industry employing them. Many quality control engineers and technicians pursue voluntary certification from professional organizations to indicate that they have achieved a certain level of expertise. The American Society for Quality, for example, offers certification at a number of levels including quality engineer certification, quality process analyst, and quality technician certification. Requirements include having a certain amount of work experience, having proof of professionalism (such as being a licensed professional engineer), and passing a written examination. Many employers value this certification and take it into consideration when making new hires or giving promotions.
Quality control engineers need scientific and mathematical aptitudes, strong interpersonal skills, and leadership abilities. Good judgment is also needed, as quality control engineers must weigh all the factors influencing quality and determine procedures that incorporate price, performance, and cost factors.
Quality control technicians should do well in mathematics, science, and other technical subjects and feel comfortable using the language and symbols of mathematics and science. Good eyesight and good manual skills, including the ability to use hand tools, are required, as is the ability to follow technical instructions and make sound judgments about technical matters. Quality control technicians should have orderly minds and be able to maintain records, conduct inventories, and estimate quantities.
Quality control engineers and technicians work with scientific instruments; therefore, academic or industrial arts courses that introduce you to different kinds of scientific or technical equipment will be beneficial. You should also take electrical and machine shop courses, mechanical drawing courses, and chemistry courses with lab sections. Joining a radio, computer, or science club is also a good way to gain experience and to engage in team-building and problem-solving activities. Active participation in clubs is a good way to learn skills that will benefit you when working with other professionals in manufacturing and industrial settings. To find out more about engineering in general, join the Junior Engineering Technical Society (JETS), which will give you the opportunity to test your skills and meet professionals and others interested in engineering, math, and science. (Visit the JETS Web site at http://www.jets.org.)
Keep in mind that quality control activities and quality control professionals are often directly involved with manufacturing processes. If it is at all possible, try to get a part-time or summer job in a manufacturing setting, even if you are not specifically in the quality control area. Although the work may entail menial tasks, it will give you firsthand experience in the environment and demonstrate the depth of your interest to future employers.
There are approximately 160,000 industrial production managers (a group that includes quality control engineers) and 69,000 industrial engineering technicians (a group that includes quality control technicians) working in the United States. The majority of quality control engineers and technicians are employed in the manufacturing sector of the economy. Because engineers and technicians work in all areas of industry, their employers vary widely in size, product, location, and prestige.
Students enrolled in two-year technical schools may learn of openings for quality control technicians through their schools’ career services office. Recruiters often visit these schools and interview graduating students for technical positions. Quality control engineers also may learn of job openings through their schools’ career services office, recruiters, and job fairs. In many cases, employers prefer to hire engineers who have some work experience in their particular industry. For this reason, applicants who have had summer or part-time employment or participated in a work-study or internship program have greater job opportunities.
Students may also learn about openings through help wanted ads or by using the services of state and private employment services. They may also apply directly to companies that employ quality control engineers and technicians. Students can identify and research such companies by using job resource guides and other reference materials available at most public libraries.
Quality control technicians usually begin their work under the direct and constant supervision of an experienced technician or engineer. As they gain experience or additional education, they are given assignments with greater responsibilities. They can also become quality control engineers with additional education. Promotion usually depends on additional training as well as job performance. Technicians who obtain additional training have greater chances for advancement opportunities.
Quality control engineers may have limited opportunities to advance within their companies. However, because quality control engineers work in all areas of industry, they have the opportunity to change jobs or companies to pursue more challenging or higher paying positions. Quality control engineers who work in companies with large staffs of quality-control personnel can become quality control directors or advance to operations management positions.
Earnings vary according to the type of work, the industry, and the geographical location. Quality control engineers earn salaries comparable to other engineers. According to the u.s. Department of Labor, the median yearly income for industrial production managers was $77,670 in 2006. The lowest paid 10 percent earned less than $47,230, and the highest paid 10 percent made more than $130,680.
The average annual salary for industrial engineering technicians was $46,810 in 2006, according to the U.S. Department of Labor. Salaries ranged from less than $30,190 to more than $79,180.
Most companies offer benefits that include paid vacations, paid holidays, and health insurance. Actual benefits depend on the company but may also include pension plans, profit sharing, 401(k) plans, and tuition assistance programs.
Quality control engineers and technicians work in a variety of set tings, and their conditions of work vary accordingly. Most work in manufacturing plants, though the type of industry determines the actual environment. For example, quality control engineers in the metals industry usually work in foundries or iron and steel plants; conditions there are hot, dirty, and noisy. Other factories, such as for the electronics or pharmaceutical industries, are generally quiet and clean. Most engineers and technicians have offices separate from the production floor, but they still need to spend a fair amount of time there. Engineers and technicians involved with testing and product analysis work in comfortable surroundings, such as a laboratory or workshop. Even in these settings, however, they may be exposed to unpleasant fumes and toxic chemicals. In general, quality control engineers and technicians work inside and are expected to do some light lifting and carrying (usually not more than 20 pounds). Because many manufacturing plants operate 24-hours a day, some quality control technicians may need to work second or third shifts.
As with most engineering and technical positions, the work can be both challenging and routine. Engineers and technicians can expect to find some tasks repetitious and tedious. In most cases, though, the work provides variety and satisfaction from using highly developed skills and technical expertise.
The employment outlook for quality control engineers and technicians depends, to some degree, on general economic conditions. The U.S. Department of Labor projects slower than average growth through 2014 for the field of industrial production management, which includes quality control engineers and technicians. This is a result of increased productivity as a result of better technology, in addition to a greater reliance on manufacturing workers to constantly monitor the quality of their own work. However, the roles of the quality control engineer and technicians are vital to production and cannot be eliminated. Thus, there will still be new jobs to replace people retiring from or otherwise leaving this field.
Many companies are making vigorous efforts to make their manufacturing processes more efficient, lower costs, and improve productivity and quality. Opportunities for quality control engineers and technicians should be good in the food and beverage industries, pharmaceutical firms, electronics companies, and chemical companies. Quality control engineers and technicians may find employment in industries using robotics equipment or in the aerospace, biomedical, bioengineering, environmental controls, and transportation industries. Lowered rates of manufacturing in the automotive and defense industries will decrease the number of quality control personnel needed for these areas. Declines in employment in some industries may occur because of the increased use of automated equipment that tests and inspects parts during production operations.
FOR MORE INFORMATION
For information on certification and student sections, contact
American Society for Quality
P0 Box 3005
Milwaukee, WI 53201-3005
ASTM International offers seminars and other training programs for those involved in testing materials and quality assurance. Visit its Web site to read articles from its magazine Standardization News.
100 Barr Harbor Drive
P0 Box C700
West Conshohocken, PA 19428-2959
Rick Munoz has been a quality assurance laboratory technician at a dental equipment manufacturing company for more than three years. He discussed his career below.
Q. Why did you decide to enter this field?
A. I became a quality assurance lab tech to build a technical foundation in my career path.
Q. How did you train for this career? What was your educational path?
A. I received technician’s training for this career. I earned a bachelor of science in electronics engineering technology.
Q. Take me through a day in your life as a quality assurance laboratory technician.A. I arrive and check the progress of all current product/material tests and resume the respective procedures for each test. Tests vary in requirements including the longevity of materials being tested, product durability through accelerated life testing, corrosion resistance to typical product usage, and the consistency of performance of new products or prototypes. All tests are diligently recorded on an everyday basis under strict guidelines. Once the test results are recorded, I create a formal report for presentation to engineers, and in some high-profile product cases, management. Quite often, I’m asked to do a retest with a refined product to see if the modification engineers have made based on prior testing improves the test result; this cycle can last a few days, or with complex products, several weeks.