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How would you identify the root cause of a recurring quality control issue in your manufacturing process?

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In the demanding world of manufacturing, quality control is paramount. When a recurring quality issue arises, it's essential to swiftly pinpoint the root cause to maintain product integrity and customer satisfaction. Identifying the root cause isn't always straightforward, but with a systematic approach, you can uncover the underlying factors contributing to the problem. By understanding these elements, you can implement corrective actions that not only fix the immediate issue but also enhance your overall manufacturing process.

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Sajad Sepidnameh

Business Development Specialist at Rimor srl
Vijay Thakor

Quality Engineer

1 Identify Symptoms

To effectively address a quality control issue in manufacturing, you must first thoroughly understand the symptoms of the problem. This involves a detailed analysis of the defect or failure, noting its frequency, severity, and the conditions under which it occurs. Documenting these observations is crucial as they serve as the initial clues in your investigative journey. With a clear picture of the symptoms, you can begin to trace them back to their potential origins within your manufacturing pipeline.

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Sajad Sepidnameh

Business Development Specialist at Rimor srl
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While gathering the information about the causes and symptoms, take care not to be deceived by the wrong information you might receive from operators. Any immediate action for solving the problem will kill your time and efficiency if not taken according to firm knowledge-based decisions.

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Vijay Thakor

Quality Engineer
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First problems are occurred which stage And after detection we addressing issues with why why analysis and we found a rout cause of the manufacturing problem and finally we take a preventive action in the problem

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Shubham Chavan

QMS Head & Management Representative, CQI & IRCA QMS Lead Auditor, Quality Management & System Implementation
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Through the investigation identify the root cause, immediately initiate product Audit for identifying the opportunity for improve the quality

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2 Gather Data

Once you've identified the symptoms, the next step is to gather data related to the issue. This involves collecting information from various stages of your manufacturing process, including machine outputs, operator inputs, environmental conditions, and material quality. It's important to compile data from both before and after the occurrence of the quality issue to identify patterns or anomalies. Analyzing this data can lead to insights about where in the process the root cause might lie.

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Andrew Yaros

Supply Chain / Manufacturing
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Collect information to determine the source of the defect and understand how significant of an issue it really is. Knowing and Creating a plan to fix the source of the problem critical. However, implementing the plan to fix the source of the problem may not be. Implementing the plan may be quick & cheap or, need a lot of down-time and/or capital investment. If the defect is within acceptable tolerance, implementing changes to the current process could make matters worse. If the defect is beyond acceptable tolerance, production may need to at least temporarily slow down to allow QC inspectors the time to scrutinize each product with greater care to sort out the defects until the solution is identified, implemented and thoroughly tested.

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3 Analyze Processes

With your data in hand, you now need to scrutinize each step of your manufacturing process. Look for any deviations from standard operating procedures that could lead to quality issues. This analysis should also consider equipment performance, staff training levels, and workflow efficiency. By examining each segment of your process in detail, you can start to pinpoint where things are going awry and why the quality control issue is recurring.

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Sajad Sepidnameh

Business Development Specialist at Rimor srl
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Asking process owners to make you aware of whatever difficulty they have working with the process, can be a rich source of information. As process owners they tend to show their knowledge and competence. Hence, in facing problems they like to be the first persons that find effective solutions.

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Mahesh Gupte

Technical Head
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Analysis is very important. At least use two different techniques to find the root cause. Like five why and 8d techniques.

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4 Implement Changes

Identifying potential causes is only part of the solution; implementing changes is where you see results. Based on your analysis, you may need to adjust machinery settings, revise protocols, or provide additional staff training. It's vital to apply these changes systematically and monitor their effects on product quality. Remember, the goal is not just to resolve the current issue but to fortify your process against future quality challenges.

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5 Monitor Results

After implementing changes, close monitoring is essential to ensure that the quality control issue has been resolved. This involves continuous data collection and observation to confirm that product quality meets your standards. If the problem persists, you may need to revisit your analysis and consider other potential causes. Continuous monitoring also helps in verifying the long-term effectiveness of your corrective actions.

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6 Refine Continuously

The quest for quality in manufacturing is ongoing, and even after resolving a specific issue, you should keep refining your processes. Use the insights gained from addressing the quality control problem to improve your overall operations. This proactive approach not only helps in preventing future issues but also contributes to a culture of continuous improvement within your organization. Regularly revisiting and updating your processes ensures that your manufacturing remains competitive and reliable.

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Gilberto Strafacci Neto (Giba)

Chief Strategy Officer | Board Member | Growth | Business Development | Autor do livro Multiverso Lean | Lean | Digital Transformation | Intelligent Automation | GenAI | Artificial Intelligence | Country Manager
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Além disso, o controle estatístico do processo tende a ser fundamental para continuidade e refinamento da análise entre varia??es de causas comuns e varia??es de causas especiais.

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How would you identify the root cause of a recurring quality control issue in your manufacturing process?

1

2

3

4

5

6

1 Identify Symptoms

2 Gather Data

3 Analyze Processes

4 Implement Changes

5 Monitor Results

6 Refine Continuously

Manufacturing

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How would you identify the root cause of a recurring quality control issue in your manufacturing process?

1

2

3

4

5

6

1 Identify Symptoms

2 Gather Data

3 Analyze Processes

4 Implement Changes

5 Monitor Results

6 Refine Continuously

Manufacturing

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