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How can you integrate your plant's quality control program with other aspects of the business?

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Quality control is a vital aspect of plant engineering, as it ensures that your products meet the standards and specifications of your customers and regulators. However, quality control is not just a technical function that operates in isolation from the rest of the business. In fact, integrating your quality control program with other aspects of the business can bring significant benefits for your plant performance, customer satisfaction, and competitive advantage. In this article, we will explore how you can achieve this integration and what are the best practices to follow.

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Staf Henderieckx

Director at Gietech BV
DEEPAK PATHAK

Business consultant
John Vanover

Quality Engineer at Sites Medical

1 Align quality goals with business goals

One of the first steps to integrate your quality control program with other aspects of the business is to align your quality goals with your business goals. This means that you should define and communicate what quality means for your plant, how it relates to your customer needs and expectations, and how it supports your strategic objectives and vision. By aligning your quality goals with your business goals, you can ensure that your quality control program is relevant, effective, and aligned with the priorities and values of your organization.

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Staf Henderieckx

Director at Gietech BV
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Quality is meeting "each" customer requirement for your product. Not capable to meet these requirements means that the company should not accept the order. Quality aligning with your company goals has another aspect: as few as possible rejection and repair. These, rejection and repair, appear because the company accepted orders that have too high quality requirements for their company quality level capability. These, rejection and repair, in case of quality level capability, appear when the operators perform incorrect comparing to the process instructions. This can be because the instructions are "incomplete" (which is 90 % of the cases) or a human error.

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2 Involve stakeholders in quality improvement

Another way to integrate your quality control program with other aspects of the business is to involve your stakeholders in quality improvement. Your stakeholders include your customers, suppliers, employees, managers, and regulators, who all have a stake in the quality of your products and processes. By involving them in quality improvement, you can gain valuable feedback, insights, and ideas on how to improve your quality standards and performance. You can also foster a culture of collaboration, trust, and accountability among your stakeholders, which can enhance your reputation and relationships.

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DEEPAK PATHAK

Business consultant
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Hello, Quality is by default. Quality never to be discussed. It shall be in built. Quality control, quality circles are old norms. Quality assurance is the right word. Quality function shall be complementary to the business needs. They shall use of all quality tools like 7QC steps, Root-cause analysis, Pareto, Histogram, Process FMEA etc. Quality shall benchmark themselves as a top class quality. Why Apple quality is not discussed since it has inherent world class quality in tis products. Product quality also ensures no product legal liability or any penalty. For painful suppliers, there is always a mitigation plan like containment wall or improving the vendor or replacing it in the last stage. Red category vendor can become Green.

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3 Use data and analytics to drive quality decisions

A third way to integrate your quality control program with other aspects of the business is to use data and analytics to drive your quality decisions. Data and analytics can help you measure, monitor, and improve your quality performance, as well as identify and solve quality problems. By using data and analytics, you can also link your quality outcomes to your business outcomes, such as customer satisfaction, profitability, and market share. This can help you demonstrate the value and impact of your quality control program to your stakeholders and justify your quality investments and initiatives.

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DEEPAK PATHAK

Business consultant
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Yes. as per my work experience, the quality decisions are critical for any organization but all quality decisions to be taken based on data & analytics. Today, Data science helps in this regards. Analytical tools shall decide the right decision based on decisive sampling plan. Data helps in deciding whether the process is stable & consistent. Cp & Cpk Values give you the process stability. Fish-bone Diagram helps in finding out the right root-cause of failure. Lean Six Sigma helps in finding out the solution for the complex issues. Six Sigma quality means 3.4 DPMO( Defects per Million Opportunities) which is the benchmark quality for any organization.

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4 Adopt a continuous improvement mindset

A fourth way to integrate your quality control program with other aspects of the business is to adopt a continuous improvement mindset. This means that you should always look for ways to improve your quality performance and processes, and not settle for the status quo. By adopting a continuous improvement mindset, you can also encourage innovation, creativity, and learning in your organization, which can lead to new and better ways of delivering quality products and services. A continuous improvement mindset can also help you cope with changing customer demands, market conditions, and technological developments.

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DEEPAK PATHAK

Business consultant
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Continuous Improvement is a mind-set. Challenging always the Status Quo situation helps continuous improvements, creativity, innovation. With continuous improvement, you get the result in terms of output, efficiency, productivity, quality etc. Continuous Improvement helps in new product launches at the right time to market. CI means positive mindset which in turn helps creativity. Those who have high EQ are good in innovation as per the results. Hence, Continuous Improvement helps the individual to become a mature & positive minded person.

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5 Implement quality management systems and standards

A fifth way to integrate your quality control program with other aspects of the business is to implement quality management systems and standards. Quality management systems and standards are frameworks and guidelines that help you plan, implement, control, and improve your quality processes and activities. By implementing quality management systems and standards, you can ensure that your quality control program is consistent, reliable, and compliant with the best practices and requirements of your industry and customers. You can also leverage the benefits of certification, accreditation, and recognition that come with quality management systems and standards.

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DEEPAK PATHAK

Business consultant
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Integrating quality management systems is always a challenge. The framework shall be conducive to the processes & not as a auditor. But the quality assurance shall have the authority to have a global recall for the faulty product from the market. Certification is one way of addressing the right quality systems in place but it does not guarantee you the assurance of the quality on time every time. It requires efforts from all departments to drive quality on time.

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6 Train and empower your quality team

A sixth way to integrate your quality control program with other aspects of the business is to train and empower your quality team. Your quality team is the backbone of your quality control program, and they need to have the skills, knowledge, and tools to perform their quality tasks and responsibilities. By training and empowering your quality team, you can enhance their competence, confidence, and motivation to deliver quality results. You can also foster a sense of ownership, pride, and engagement among your quality team, which can boost their morale and retention.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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John Vanover

Quality Engineer at Sites Medical
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A bit of a caution about these ideas. As you are implementing changes, ask yourself if you have created a fox in the hen house situation. For example, quality and operations can be checks and balances to one another. If you move something into operations court, and have created a situation where they are completely in control of a critical aspect of a product? And do they property understand their new responsibilities. Our are they of the "quality will catch it" mindset. This can be why a pfmea can be very helpful when reviewing system changes.

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How can you integrate your plant's quality control program with other aspects of the business?

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1 Align quality goals with business goals

2 Involve stakeholders in quality improvement

3 Use data and analytics to drive quality decisions

4 Adopt a continuous improvement mindset

5 Implement quality management systems and standards

6 Train and empower your quality team

7 Here’s what else to consider

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