How can you ensure production quality is maintained despite unexpected breakdowns?

To maintain production quality during unexpected failures, a comprehensive approach to reliability management and recovery should be implemented. The use of predictive analytics and IoT sensors allows you to identify potential problems before they occur, minimizing downtime. Optimization of maintenance procedures through the TPM (Total Productive Maintenance) system ensures systematic elimination of weak points in equipment. It is also important to implement agile management methodologies such as SMED (Single-Minute Exchange of Die) for rapid response and recovery. Training personnel based on best practices and regular training on prompt troubleshooting also significantly increases the resilience of production to failures.

Según mi experiencia, generar procedimientos de calidad que cubran los posibles inconvenientes que se puedan generar durante la producción, como ser, falta de personal, roturas y fallas mecánicas o fallas de cargas y parámetros de maquinas. Los procedimientos deben ser realizados conjuntamente con ambos dptos. (producción y calidad).

O seguimento contínuo do plano de controle e trabalho, assinala bem esse cenário, garantido a qualidade do produto pelo método.

You've got to have a high risk tolerance. You've got to go from "definitely won't hurt me" to "I don't know, should be fine". Production is money, have the common Run To Fail spare parts. Breakdown maintenance sucks. If you can make sure you have a understanding of how the machine works. That will allow you to come up with good bandaid fixes until a shutdown occurs. If you don't do regular shutdowns (overhauls/inspections of your equipment) ensure it becomes apart of the regular maintenance schedule.

As the production tooling, equipment, or work in process (WIP) may be compromised due to the breakdown, the written procedures for start-up should be followed. They might include quarantine and extra inspection of WIP as it is completed and/or first article inspection (FAI) after repairs are completed. Look towards your process failure mode and effects analysis (PFMEA) documents for leadership in this case.

Understanding the various aspect of manufacturing is key. Though there could be so many things in manufacturing process those could be common across the industries. Important aspect is Understanding your specific requirements. If orthodox methods are not delivering the desired results then ofcourse one needs to be specific and interactive. All the other methods mention are essential but knowing your specific manufacturing needs Is key for consistent quality.

If we assume that you already are experiencing problems with the equipment, there is no way to prevent the occurrence of quality issues. We can react for sure once the problems are present, but when the equipment is contributing to the generation of problems, How can anyone ensure the quality of the products? No one. The focus of this scenario should be based in preventive actions, that are mentioned by other experts. The “normality” when a machine is “letting us kwnowing that it is close to fail, is to keep forward until defects shows up. Need to change mindset and move from a reactive to a preventive approach.