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What do you do if logical reasoning fails to ensure quality control in automotive manufacturing?

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In automotive manufacturing, quality control is paramount. It's a complex dance of precision engineering, where every part must fit perfectly and function seamlessly. But what happens when logical reasoning, the backbone of troubleshooting and process optimization, falls short? It's a scenario that can leave even the most seasoned professionals scratching their heads. In such cases, it's essential to explore alternative strategies to maintain the high standards that the automotive industry demands. This article delves into what you can do when logic alone doesn't cut it in ensuring quality control in automotive manufacturing.

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Leandro Nahuel Zárate

Técnico en Control de Calidad VASA. Vidriería Argentina S.A
Ashis sen

An Innovative & Decisive leader & Techno-Commercial person using Spinning Technology & Modern Management skills to…
Rogério Santos

Analista da Qualidade | Auditoria | Qualidade de Fornecedores | SGQ | PPAP | APQP | IATF 16949 | RNC | 8D | MASP |…

1 Assess Data

When logical reasoning meets a dead end in automotive manufacturing quality control, your first step is to reassess the data. Look beyond the obvious and scrutinize the information from different angles. Sometimes, the issue may not be with the process but with the data itself. Ensure that the data collection methods are accurate and that the data is being interpreted correctly. Misleading data can send you on a wild goose chase, so it's crucial to confirm its reliability before making any decisions.

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Prince Rai

Engineer and explorer
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First of all we should go through multi dimension approach while solving quality related problem. Sometime quantitative data analysis like pareto chart can not solve quality issues because one defect is directly or indirectly connected with another defect (support 100 dent & 17 gauge NG issues) .... let we get dent while hammering or truing then we have to reduce focus on truing to reduce chances of dent because both are interconnected. Which result in gauge NG . Gauge NG is serious issue in fitment assembly. Therefore corrective action through root cause analysis , then preventive action by considering all potential causes is best way .

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JOSEPH SYLVESTER BARLOW

Quality Head @Groyyo
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REASSESS THE DATA LOOK BEYOND THE OBVIOUS AND SCRUTINIZE THE INFORMATION FROM DIFFERENT ANGLES. SOMETIMES, THE ISSUE MAY NOT BE WITH THE PROCESS BUT WITH THE DATA ITSELF ASSESS DATA/ROOT ANALYSIS/EXPERT CONSULT/INNOVATIVE TECH/PROCESS REVAMP/CONTINUOUS TRAINING

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2 Root Analysis

If logic fails, delve deeper into root cause analysis (RCA). This methodical approach helps you identify underlying issues that aren't immediately apparent. RCA involves examining the problem beyond its symptoms, looking at everything from materials to machinery to human factors. By systematically eliminating possible causes, you can uncover hidden defects or process inefficiencies. This thorough investigation often reveals solutions that pure logic might miss.

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Rogério Santos

Analista da Qualidade | Auditoria | Qualidade de Fornecedores | SGQ | PPAP | APQP | IATF 16949 | RNC | 8D | MASP | METROLOGIA | MSA | GD&T
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Uma vez com o auxílio dessa metodologia descobrimos que as "marretadas" que um operador dava para encaixar uma bucha era a causa da sua N?O MONTAGEM. E todos buscando laudos de propriedade mecanica, química. Certificados, laudos de zincagem. etc. E a causa era bem simples.

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Charlon Costa Leite

Especialista da Qualidade / Engenheiro mecanico.
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Um exemplo que já vivenciei foi quando estava na análise dos 5 porquês, e essa ferramenta, foi utilizada de forma tendenciosa com isso nos desviando da dire??o da causa raiz de um problema de grau "A" automotivo.

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3 Expert Consult

Sometimes, you need to tap into collective wisdom. If you're stumped, consulting with experts in the field can provide fresh perspectives on quality control challenges. These professionals have a wealth of experience and might have encountered similar issues. Their insights could lead to innovative solutions that your logical reasoning alone might not have generated. Collaboration is key in the complex world of automotive manufacturing.

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Benjamin Garcia

Quality Control Specialist
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Sometimes the reasons for the failures are created from a term called “travel knowledge” which is sometimes misinterpreted by experience.

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4 Innovative Tech

Embracing innovative technologies can be a game-changer when logical reasoning falls short. Advanced tools like artificial intelligence (AI) and machine learning (ML) can analyze vast amounts of data and recognize patterns that humans might overlook. These technologies can predict potential faults and suggest preemptive measures to maintain quality standards. Investing in such cutting-edge solutions can give you an edge in problem-solving.

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5 Process Revamp

At times, the problem lies in the very foundation of your processes. If logical reasoning isn't helping, it may be time to revamp your manufacturing processes. This doesn't mean a complete overhaul but rather making strategic adjustments that can have a significant impact on quality control. Look at your processes from a fresh perspective and be open to making changes that could resolve persistent quality issues.

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Leandro Nahuel Zárate

Técnico en Control de Calidad VASA. Vidriería Argentina S.A
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Es importante realizar análisis del proceso, teniendo en cuenta que hay a veces se limita al control no garantizando calidad.

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6 Continuous Training

Lastly, never underestimate the power of continuous training and education for your workforce. When logic alone doesn't resolve quality control issues, it might be due to a knowledge gap or a need for skill enhancement. Providing regular training on the latest manufacturing techniques and quality control measures ensures that your team is equipped to tackle challenges effectively. A well-trained workforce is an invaluable asset in maintaining high-quality standards.

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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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Ashis sen

An Innovative & Decisive leader & Techno-Commercial person using Spinning Technology & Modern Management skills to ensure Standard Productivity & optimum Quality at minimum cost to achieve & improve Organisational Goal
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Implementation of the key findings from Root cause analysis, continuous learning, continuous skill development, SOP upgradation & training the team on upgradation, last & not least, learning from others' mistakes is a big key to quality control

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What do you do if logical reasoning fails to ensure quality control in automotive manufacturing?

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1 Assess Data

2 Root Analysis

3 Expert Consult

4 Innovative Tech

5 Process Revamp

6 Continuous Training

7 Here’s what else to consider

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