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Last updated on 2024年8月2日

What are the most common quality issues in production operations and how can you prevent them?

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Quality issues in production operations can have serious consequences for your business, such as customer dissatisfaction, increased costs, wasted resources, and regulatory compliance problems. To avoid these pitfalls, you need to identify and prevent the most common causes of quality defects in your manufacturing processes. In this article, you will learn about six of the most frequent quality issues in production operations and how you can prevent them with effective quality management techniques.

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Sanjay Kulshrestha

Asst. Vice President Quality Management at NAHAR FABRICS SAP QM
Hector Lugo

Quality Engineer

1 Human error

Human error is one of the most common and inevitable sources of quality issues in production operations. Human error can occur at any stage of the production process, from design and planning to execution and inspection. Some of the factors that can contribute to human error include lack of training, fatigue, stress, distraction, and poor communication. To prevent human error, you need to provide adequate training and supervision for your employees, implement clear and consistent procedures and standards, use checklists and visual aids, and encourage feedback and collaboration.

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Hector Lugo

Quality Engineer
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In my opinion and experience, using a poka-yoke device with which prevents a human error from occurring or makes a human error very obvious. This device offers a better option to organizations than training and supervising employees because poka-yoke are more effective.

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2 Equipment failure

Equipment failure is another common cause of quality issues in production operations. Equipment failure can result from wear and tear, improper maintenance, calibration errors, power fluctuations, or environmental conditions. Equipment failure can affect the quality of your products by causing defects, deviations, or variations in the output. To prevent equipment failure, you need to perform regular preventive maintenance and inspections, use reliable and compatible equipment, monitor and control the operating conditions, and have contingency plans for emergencies.

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3 Material inconsistency

Material inconsistency is a quality issue that arises when the raw materials or components used in your production operations are not of the same quality, specification, or origin. Material inconsistency can affect the quality of your products by causing variations in the performance, appearance, or functionality of the output. To prevent material inconsistency, you need to source your materials from reputable and certified suppliers, verify and test the quality of the incoming materials, store and handle the materials properly, and trace and document the material flow.

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4 Process variability

Process variability is a quality issue that occurs when there are variations in the production process parameters, such as time, temperature, pressure, speed, or flow. Process variability can affect the quality of your products by causing variations in the output characteristics, such as size, shape, color, or weight. To prevent process variability, you need to standardize and optimize your production process, use statistical process control (SPC) tools to monitor and control the process variables, and implement corrective and preventive actions (CAPA) to address any deviations or anomalies.

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5 Design flaws

Design flaws are quality issues that stem from errors or shortcomings in the design of your products or processes. Design flaws can affect the quality of your products by causing defects, failures, or inefficiencies in the output. To prevent design flaws, you need to follow a systematic and rigorous design process, such as the design for manufacturing (DFM) approach, which involves considering the manufacturability, functionality, reliability, and cost-effectiveness of your products or processes. You also need to conduct thorough testing and validation of your designs, and incorporate feedback and improvement cycles.

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6 External factors

External factors are quality issues that are influenced by factors outside your direct control, such as customer requirements, market trends, regulatory standards, or environmental conditions. External factors can affect the quality of your products by causing changes in the expectations, preferences, or needs of your customers or stakeholders. To prevent external factors, you need to stay updated and informed about the external environment, communicate and align with your customers and stakeholders, and adapt and innovate your products or processes to meet the changing demands.

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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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Sanjay Kulshrestha

Asst. Vice President Quality Management at NAHAR FABRICS SAP QM
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1.Making Money Claiming faults 2.Hide Pre Discount Commitment on Quality base 3.Over Quality Commitment Commitment without considering capacity and capabilities 4.Commitment to Defeat Competitor Market 5.Quality commitment by non Quality Person 6.Administrative Approach without Learning Reality 7.Threatening from Customer 8.Non Allign Team Faults Finding and Blame Environment 9. Price Fluctuations , Delaying in delivery 10. Cancelation by end users Top Management must be capable enough to learn the reality Quality is not always at faults there are lot many other factors which works behind the Quality Quality Department can offer best or manage as available but can not replace the product or service

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Turhan Bektas

Sr. Team Lead at Bausch + Lomb
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Common quality issues in production include defective products, inadequate training, inaccurate documentation, supply chain problems, process variability, change management, and regulatory non-compliance. Preventing these issues involves measures like equipment maintenance, employee training, good documentation practices, supplier quality management, process control, change control, and regulatory compliance. Continuous improvement and environmental control are also key. A structured quality management system can help address and prevent these issues.

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What are the most common quality issues in production operations and how can you prevent them?

1

2

3

4

5

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1 Human error

2 Equipment failure

3 Material inconsistency

4 Process variability

5 Design flaws

6 External factors

7 Here’s what else to consider

Manufacturing Operations

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What are the most common quality issues in production operations and how can you prevent them?

1

2

3

4

5

6

7

1 Human error

2 Equipment failure

3 Material inconsistency

4 Process variability

5 Design flaws

6 External factors

7 Here’s what else to consider

Manufacturing Operations

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