You're striving for manufacturing efficiency. How can you ensure product quality doesn't suffer?

I truly believe that the focus should always be in “Process’ Quality” rather than “Product’s Quality”..by focusing on eliminating waste, non value added steps by using lean initiatives, reduce idle time through SMED, etc will help to improve overall process without affecting the product itself. If everyone’s focus is in standardizing the process, applying the proper PM program to equipment, and deploying the appropriate training to operators, the process will become so stable and predictable that will guarantee quality on the end product 100% of the time.

Part quality is one of the top items to improve when considering efficiency improvements. You cannot decrease machine cycle time at the cost of part quality to improve true efficiency. To achieve a goal of increased efficiency there has to be a heightened awareness of how it affects the part quality. Lower cycle times are always good for the bottom line but equipment has a threshold and when it is crossed the hazard of decreasing part quality greatly increases. The bottom line is that if you are running really fast but producing high numbers of NG parts your efficiency did not increase. It may have even decreased.

I had once a sensei that told me "Ignacio, the day you become an expert in Lean, instead of adding, you are going to remove" what does that mean? We always have to facilitate the operator's operation, and not the other way around, the operator is the surgeon of the operation, let's make it simpler.

Common sense says remove and/or minimize steps that do not add value for the customer. Shorten distances to get things or move things. Sitting and waiting are also items to address

Cada día les digo al equipo de producción la calidad comienza cuando toman el primer tornillo, tuerca y arandela. Esperar que el inspector de calidad encuentre los errores, es la peor estrategia. Cada integrante del equipo debe ser consciente de la calidad; solo así lograremos una cultura de calidad en cada etapa del proceso.

Do what you say and say what you do. This is a constant feedback loop for standard work. This also allows you to update your procedures as better ways are found to improve the process.

In short: VA/VE, implementation of PokaYoke, automation of processes and quality control (among other tools and mathods) will ensure that quality doesnt suffer. Quality should be built into the process and that's where the focus should be, rather than in product itself.

Make sure you stay on task and don't distract employees too much. We all fail to have 100% bandwidth, 100% of the time. Focus on the customer and make sure your employees understand the link from what they do to how it affects the customer.

La capacitación muchas veces es considerado como un gasto, lo peor que podemos hacer es no capacitar al personal y esperar que cada día lo hagan mejor. Si no hay quien les ense?e ha realizar mejor su trabajo, seguirán haciendl

A perfect machine yields perfect product. Ask yourself if your machine is perfect and is it given the attention it needs. This mentality helps prime for action.

This is what Six Sigma and Lean is trying to achieve. Reducing variation and reducing waste helps towards an optimized process.

El gran reto al optimizar los procesos es identificar que si agrega valor al proceso y al producto. Una vez identificado debemos considerar que se debe dejar de hacer, y enfocarse en lo que si agrega valor