Ensuring quality control without halting production: Can you maintain efficiency while enhancing standards?

Do the right things at first time to prevent rework, remake at the later stage. Perform VSM study to ensure the smooth flow and no bottleneck in the whole line.

Maintaining efficiency while enhancing standards is achievable with effective quality control measures. Statistical In-Process Controls have been in place since the 1920's, pioneered by Walter A. Shewhart at Bell Laboratories and later applied by W. Edwards Deming during World War II: concurrent to non-stop production, ensuring that variables stay within defined limits. Validated Methods: Using validated methods for quality control helps in consistently achieving high standards. Continuous Monitoring: Regular monitoring and adjustments can prevent deviations and maintain efficiency. Training and Communication: Ensuring that all team members are well-trained and informed about quality standards can enhance overall efficiency.

Yes we can incorporate the quality control into the production without affecting the production of products. The things we can incorporate into the production are; (1). Lean manufacturing process (on which we can eliminate the things which are not required in the work place. And eliminate the wastage in the workplace area. (2). We incorporate 5-S (in which we do the things which are important for production otherwise we eliminate the things which are not required. Like- shorting, selection, cleaning, standardization the things)-these things we do, we definitely increase the production. (3). Kaizen's Principle (in which we can change or eliminate things for Better production.

Yes Take sanitation as an example. Investments into CIP or cleaning station layout with 5S approach can drastically reduce down time and result in more consistent results which is a reliability component add to the Quality control of any process. (Less Task Time - Improved Results)

Start at the beginning with APQP, installing a robust process flow, FMEA and Control Plan, then monitor the process using SPC, which gives you an early warning when you are going out of control. Couple this with a decent 5/6S programme, and you’ll be off to a great start. Important to do this properly, don’t just pay lip service ??

The new opportunities for real time data collection are extensive. The challenge is converting this data into information that enables decision making. Dimensional data from part measurements is well understood, but in-process vibration data from a machining operation, for example, may require additional interpretation. Including domain experts on your data team could enable improved decision making and increased productivity. Multi-disciplinary data teams is my recommendation.

Let us take Statistical Process Control as a tool for the real time data analysis In the past Lean Six sigma programs our traditional approach is to perform process baseline using SPC to establish process capabilities using history data . This will allow to dig opportunities from the past happening to prioritise improvement areas , but the damage is already done . The real time monitoring of processes using advanced SPC tools such as SPACE( from Camline which was extensively used in semiconductor industries) make use of real time data so any process deviation is immediately deducted and all common cause problems are addressed real time with continuous enhancement of preventive process controls . This results in huge cost avoidance

In process inspection is widely used within the industry. This catches flaws as they occur. A big offender is broken tooling, that the operator failed to catch, due to distractions, or simply not paying close attention.

O que podemos dizer é que estes problemas, em sua maioria, s?o causados por: Varia??es na matéria-prima; Erro humano; Falhas no maquinário e nos equipamentos; Uso incorreto dos métodos e procedimentos produtivos; Falha no processo de inspe??o.

Ferramentas de qualidade e software que identifique cada passo dado nas eventuais corre??es torna o processo cada vez mais fácil de sanar eventuais falhas e problemas!

This is not a requirement, especially when the cost of automation cannot be justified with a good ROI. On that case, it would be better to stick with humans because they are relative smarter (smarter automated system exist but they are too expensive), also the issue of repetitive tasks can easily be tackled by scheduling the labor into shifts to minimize boredom and tiredness. Other upsides of sticking with human is that they are flexible and decisive.

Garantizar el control de calidad sin detener la producción es viable mediante tecnologias de automatizacion. Automatiza la inspección con sistemas de visión artificial y sensores para monitoreo en tiempo real. Implementa ciclos PDCA y empodera al personal para identificar y resolver problemas. Usa el control estadístico de procesos (SPC) para detectar y corregir variaciones antes de que impacten la producción. Aplica principios lean para eliminar desperdicios y adopta las 5S para mantener el orden. Realiza mantenimiento preventivo y predictivo de equipos. Con estas estrategias, es posible mantener la eficiencia y mejorar los estándares de calidad simultáneamente.

Facilidade nas inspe??es e controle de processos torna a produ??o com condi??o melhor de monitoramento e controle estatístico!

Have some Go-No Go tooling made to speed up inspection process. Instead of having to measure with precision tooling. Eliminate having to open tools to there maximum.

Automation technology is transforming quality control in manufacturing by enhancing precision, speed, and efficiency. Robotic systems and automated inspection tools offer unparalleled accuracy, surpassing human capabilities. The seamless integration of automation technology optimizes production processes, ensuring high product quality while minimizing defects. Despite initial investment costs and training requirements, the long-term benefits of automation in quality control are significant. Advancements in AI and Industry 4.0 are driving innovation, reshaping the future of quality control in manufacturing. Embracing automation technology is essential for manufacturers to stay competitive and achieve operational excellence.

I couldn't agree more. A well trained staff will have more confidence in the final product. They will also hold each other accountable for the entire process.

O treinamento é mais uma ferramenta da qualidade que leva qualquer processo a perfei??o! Treinar e atualizar os colaboradores sempre!

El entretamiento de los empleados es la herramienta principal para aseguarar el camino al exito, ya que el empleado tiene el acceso a todas las areas EHS, Mantenimiento, Operaciones, Calidad y mas Ademas, se genera la cultura del conocimiento que hace que ese aprender llegue a la familia, asi contribuyendo con la mejora profesional y personal

Employee training is most effective factors to improve Product Quality. Increase productivity. Reduce process rejection. Reduce market complaint also. It can be reduced raw material rejection als0.

Having everyone on the same page for acceptance criteria. For instance everyone's interpretation of what's relevant and what's not, the same. I can assure you, this helps a lot.

é uma estratégia que visa alinhar os objetivos e processos entre uma empresa e seus fornecedores, transformando-os em verdadeiros parceiros de negócios.

1. Early Quality Control: Ensure raw materials and components meet quality standards before reaching the production line. 2. Supplier Integration: Incorporate suppliers into your quality management system for better oversight. 3. Clear Communication: Establish strong communication channels and clear quality expectations with suppliers. 4. Reduced Inspections: Minimize the need for extensive incoming inspections, streamlining the production process. 5. Smooth Production: Maintain a consistent and efficient production line by ensuring high-quality inputs from suppliers.

Install APQP at your suppliers, then your process will be much easier to control up front . You’ll also encourage a partnership with your suppliers which will pay you dividends ??

Collaborate closely with suppliers to ensure raw material quality. Action: Share performance data with suppliers and set up joint quality improvement initiatives, ensuring consistent input quality and reducing production issues.

Encourage a culture of continuous improvement using PDCA cycles. The PDCA/PDSA cycle is a continuous loop of planning, doing, checking (or studying), and acting. Action: Regularly hold review meetings to discuss feedback, conduct root cause analysis, and implement corrective actions, driving ongoing enhancements in quality and efficiency.

Melhoria contínua é um conjunto de práticas e a??es implementadas por diversas empresas ao redor do mundo, com o objetivo de obter melhores resultados e um bom aproveitamento em processos internos e também nos processos de venda de um produto ou servi?o, melhorando a qualidade.

Continuous improvement. improve productivity. That is reduce process rejection. It can be improve Quality of products. Reduce extra manpower cost.

Garantizar el control de calidad sin detener la producción es viable mediante la mejora continua. Automatiza la inspección con sistemas de visión artificial y sensores para monitoreo en tiempo real. Implementa ciclos PDCA y empodera al personal para identificar y resolver problemas. Usa el control estadístico de procesos (SPC) para detectar y corregir variaciones antes de que impacten la producción. Aplica principios lean para eliminar desperdicios y adopta las 5S para mantener el orden. Realiza mantenimiento preventivo y predictivo de equipos. Con estas estrategias, es posible mantener la eficiencia y mejorar los estándares de calidad simultáneamente.

Continuing to improve at anything in life is always a win. This is especially the case when it lightens the load for those that are already feeling overwhelmed. Listening to the help at the bottom is a great starting point on this. They are hands in all day and may not know exactly how to make it better, but listening to there insight and bouncing ideas off the wall can really create change.

Adotar essa prática no processo organizacional traz inúmeros benefícios que impactam diariamente nos resultados da empresa. Dentre os benefícios, destacamos o estímulo para o trabalho em equipe, pois unindo diversos profissionais em um ambiente colaborativo, as oportunidades de aprendizado s?o imensas.

Simplify the process ... or some would say dummy it down, initially. This is an effective way to train. Then as time goes on, keep enhancing your team with knowledge as to why, how, for what... This eliminates confusion, creates confidence, and allows people to feel a level of ownership to the task. Very affective

In some cases Quality Control personnel with mechanical experience, can repair as they inspect. This to save time of components having to be reprocessed through the system.