How can you reduce defects in a product?

In my experience identifying root cause is cornerstone for proactively reducing repetitive defects. Various types of tools such as fishbone diagrams, Pareto charts, or 5 whys can be used to analyze the sources of variation and error in product or process. By finding out the most critical factors that contribute to defects, you can prioritize your improvement actions and focus on the areas that need the most attention.

To reduce product failures, a systematic approach centred on preventive is required. I would begin by extensively examining the manufacturing process to find potential failure points. This could include approaches such as statistical process control to discover variations and root cause analysis to determine why failures arise. Once high-risk regions have been identified, robust solutions, such as error-proofing machinery, optimising operating settings, or improving quality control inspections, can be applied. Continuous performance monitoring and fine-tuning of remedial procedures allows for long-term defect reduction and process capability increases. The goal is to include quality across the value chain.

This sounds simple but really isn't. Make sure to both identify applicable methods and to then analyze their use over time. Things change and you can't depend on processes to improve themselves, even with incentives. QC applies to ANY process, human/automated/hybrid. Famously, things like checklists can help improve delivery of quality production, but can dissuade inspectors from seeing emergent issues (i.e. shift differentials in in materials, design changes with no criteria properly defined, etc.). A QC maintenance process itself needs to be QC'ed.

To identify issue in process and product is not much easy as seems. Some time very minute issue can be cause of defect which everyone neglected. So how we can cover all this issue in one short The answer is brainstroming with all process owner ( From product/process passes) involvement of all person is very important Then seat to find root cause ( That means causes that can be one of reason) We have some Six sigma tools for this like Fishbone, 5- WHY, Parto, 8 D these are measur and impactful tools so we can get root cause.. ones u have RC then you can plan to improve that issue as you have already process expert. If not then Six sigma professionals can help you out.

In modern commercial supply chains, you are merely moving goods from upstream producers to downstream users (hopefully adding value). But when a defect is identified, you need to be a central dispatch for information. Is it a defect? Is it a different use case than the product is designed for? Is it a performance, design, delivery or expectation defect? Making sure your suppliers know what was "wrong", helping your customers define a defect in detail, and keeping the information flowing actively is far more important than just solving the problem. Most defects in industry have multiple sources, may not be a defect but a design flaw, and need feedback in both directions to address Be the valve, the filter, and the pump in that flow.