How would you address a sudden increase in defective automotive parts during production?

01 Inspecionando matéria prima 02 Mapeando o processo de produ??o 03 Montando uma MASP método de solu??o de poblema. Fazendo reuni?es com os colaboradores checando informa??es, abrindo alertas de Qualidade e A??es de ocorrência correntiva e preventiva.

Durante a minha experiência com tratamento térmico de produtos automotivos, utilizávamos uma abordagem estruturada para lidar com reprova??es de propriedades do material. Ao identificar alguma n?o conformidade, a produ??o era interrompida imediatamente para avaliar todos os parametros de processo e condi??es dos equipamentos. Uma vez identificada uma n?o conformidade, conduzíamos uma análise detalhada com uma equipe multidisciplinar, que incluía membros das áreas de Produ??o, Manuten??o e Engenharia. Utilizávamos ferramentas como o Diagrama de Ishikawa e 5P para identificar a causa raiz e, assim, definirmos um plano de a??o eficaz.

If there's a sudden rise in defective parts, here's what we’ll do: 1) Pause Production: Stop, Call, Wait. Stop making parts to avoid more defects. 2) Identify Issues: Check 4Ms to find the root cause. 3) Fix Problems: Normalize the 4Ms and ensure all important items are corrected. 4) Test and Resume: Run a test batch to confirm fixes, then gradually restart production. 5) Learn and Improve: Analyze the problem, update procedures, and document lessons learned.

If it’s a sudden increase- I would want you know if/what changes have been made. Operators/the team working on the floor would give me that input.

If quality was within specified tolerances as listed in the SOP, or the company's QA guidelines and suddenly trended downwards. I would recommend first, stopping the bleeding (or production) to control your wasting of raw materials, reliability % and rework time to correct the issue (if possible) which equals $$$ down the drain. Next, use some intelligent thought processes to determine the cause of said quality drop. Ask: Is this an issue we've seen before? Most problems are! Determine whether its a supplier issue, mechanical issue or human error. Lean 6 sigma will precisely determine the problems' source. Apply DMAIC to improve alrready existing quality control methods, or upon a newly defined root cause you should apply DMADV.

Ao longo da minha experiência, desenvolvemos um forte envolvimento com a equipe diariamente, especialmente com materiais automotivos. Dada a importancia dos parametros de processo a serem atendidos, nossa equipe tinha total autonomia para interromper o processo caso algum parametro n?o fosse atendido. Em seguida, discutíamos as possíveis causas do ponto de vista operacional. Essa atitude fomentou o senso de propriedade e responsabilidade de todos com o processo, independentemente da fun??o e abertura de observa??es e sugest?es por parte da equipe.

The operators should have some of the best feedback on the overall success rate of the company's production methods in relation to reaching the targeted finished product deadlines. In the past experiences I've shared with my friends and work families so to say, input from "team members" who are new, through a staffing agency or simply part time might not be as valuable as one might hope.?? Sometimes it is.. However, it seems to be (to me) in the best interest of the company to comprise specific teams for individual areas of the production floor. I've seen more innovative ideas, as well as safety oriented procedures implemented by upper management, of course, but realized by coworkers that WANT to make a difference.

1-J'analyserais rapidement les causes racines. 2-Mettrais en place des contr?les supplémentaires. 3-Ajusterais les processus de production pour réduire immédiatement le taux de défauts tout en prévenant les récidives.

Ao longo da minha experiência com tratamento térmico, tínhamos um procedimento eficaz para ajustes de processo. Quando um ajuste era identificado na análise de causa, um engenheiro responsável pelo produto emitia uma Altera??o Temporária. Esse procedimento permitia que a produ??o continuasse até que toda a documenta??o fosse atualizada e toda a equipe fosse devidamente treinada.

Improve the technical skills Adaptation to new technologies. Use all certified information sources and make them easy to access. Consider the customer satisfaction and trust and improve them as first priority.

Assemble a team with members from manufacturing, quality, production and process engineering, and perform an 8D Root Cause Analysis event.

If it comes down that defects are due to supplier issues, be sure to relate all your defect concerns to your supplier. It’s important to include photos of defects found along with traceability details (ex., PO, Date Code(s), quantities, etc.). When needed, always request Corrective Actions from your supply base regarding defective product. When possible, include your company Purchasing Rep’s in the situation to keep them in the loop and assist with the process, as needed. Also, regular auditing of your approved suppliers is also very important for continuous improvement!