How do you balance defect prevention and correction in manufacturing?

2 Implement prevention methods

The next step is to implement methods that prevent defects from occurring in the first place. Prevention methods can reduce the sources of variation, error, and waste that cause defects. Design for quality involves designing the product and process to meet quality standards and customer needs while process control involves monitoring and adjusting parameters and inputs. Poka-yoke is a Japanese term meaning "mistake-proofing" and it refers to any device or technique that prevents or detects human errors. Training and education provide staff with the necessary skills, knowledge, and tools to perform tasks correctly. Supplier management involves selecting, evaluating, and collaborating with suppliers to ensure delivery of quality materials, components, or services that meet specifications. All of these prevention methods are essential for ensuring defect-free products.

3 Apply correction methods

Despite your best efforts, some defects may still occur in your manufacturing process, necessitating methods to correct and prevent them from reaching the customer. To do so, you should inspect and test the product or process at various stages to verify that it meets the defect criteria and quality standards. This can be done manually or automatically, using tools such as gauges, meters, scanners, or cameras. Additionally, sorting and rework involves separating defective products from the non-defective ones, and either repairing, modifying, or replacing them to meet quality requirements; this can be done in-house or outsourced. Lastly, scrap and recall involves disposing of or returning defective products that cannot be repaired or reworked; however, this can be costly and damaging to your reputation, so it should be avoided as much as possible.