Struggling to align quality control and production?

SPC ist sicherlich hilfreich aber die Mitarbeiter die damit umgehen müssen machen das ganze erst interessant. Regelkarten zu interpretieren und dir richtigen Rückschlüsse zu ziehen ist ein anderes Thema.

Como promover a Otimiza??o de Processos Industriais? Definindo Metas Claras: Estabele?a metas específicas e mensuráveis para a otimiza??o de processos, como redu??o de custos, melhoria da qualidade, aumento da eficiência produtiva, etc. Isso ajuda a direcionar os esfor?os e motivar a equipe.

Aligning quality control with production requires a balanced approach that addresses both immediate needs and long-term goals. Short-term fixes provide immediate relief, while long-term solutions ensure sustainable improvements. By implementing preventive maintenance, investing in new equipment, redesigning workflows, adopting lean principles, and enhancing staff training, manufacturers can achieve a harmonious balance between quality and production efficiency. This integrated approach not only improves product quality but also enhances overall operational performance, leading to higher customer satisfaction and business success.

Cuando se inicia un nuevo proyecto hay que empezar por elaborar un AMFE de dise?o y procesos eficiente , esa evaluación es clave para prevenir problemas futuros. Establecer los procesos de producción en base a los resultados obtenidos en los AMFE, trasladarlos a unas HOE fáciles de entender. La otra fase importante es la formación del personal de producción , donde se deben testear los procesos establecidos. La retroalimentación debe ser continua hasta minimizar los errores. Apoyarse en la tecnología , implementando el sistema Poka-Yoke en las partes del proceso más vulnerables . En resumen, implementar las mejores herramientas prácticas, de automatización y sistemas .

Hola Colegas... en mi experiencia uno de los puntos mas importantes de alinear la producción y el control de calidad es tratar de fusionarlos a nivel operativo, es decir, la calidad en la fuente. Esto no se da solo con empoderar al operador, no, esto viene acompa?ado de tener documentación operativa (procedimientos, ayudas visuales, instructivos, etc) y capacitación muy a detalle para que los empleados operativos sean parte del mismo control de calidad, Siempre reforzados con un equipo de inspectores. Luego trabajar en que los equipos operativos sean parte de los análisis de causa raíz y que ellos mismos tengan un indicador que si cumple las metas, los empleados tengan acceso a un bono especial mensual.

Si puedes realizar un cruce entre el mapa de procesos, el layout de planta, aplicar cadenas de Markov para ver cómo va la producción en planta, podrás controlar de mejor manera la productividad. Si se le a?ade la gestión de activos para conocer si hay partes que se encuentran detenidas y el costeo de producción, tendrás una visión clara de tus capacidades. No he encontrado software que me permita ver de esta forma la planta, lo intentamos programar por nuestra cuenta en la empresa, espero que una vez terminado pueda aplicarse a otras industrias y se aporte a la planificación de producción de mejor forma.

Process mapping is essential to know what your process is like and be able to control it. On many occasions, the real processes are different from the theoretical ones. That is why the first step to making any decision is to know your process properly.

Process mapping is a technique used to visually represent the steps involved in a process. It helps in understanding how a process works and identifying areas for improvement(Bottle Necks). By creating a diagram of the workflow, teams can see the sequence of actions, decision points, and the flow of information or materials.

Uso o mapa de processos para entender os fluxos, os pontos e métodos de controle, cada etapa de fabrica??o. Essas etapas depois s?o desdobradas, e avaliados os detalhes de cada uma delas. Algumas metodologias contém ferramentas práticas e funcionais. Costumo usar ferramentas Lean Manufactoring e Six Sigma. O mapa de processo é uma "foto" macro do que acontece e como acontece, ajuda a entender e propor mudan?as, melhorar eficiência e eficácia, ter clareza do que se faz, porque se faz e pra quem se faz.

Adapting to lean practices will for sure bring in quality product, but it is importan t to understand which lean tool will be ideal for the scenario and the concepts to be implemented should have a robust roadmap with key success factors for the concepts to be adapted and successfully implemented. This process requires a lot of patience but this for sure brings in the desired results with sustainability.

O conceito " Lean" pode ser aplicado em varios processos. A base desse conceito esta em fazer mais com menos , literalmente falando, pois, as premissas do Lean consiste na elimina?ao dos 7, 8 desperdi?ios que afetam uma cadeia produtiva, sao eles : Tempo de espera, Retrabalho,estoque , superprocessamento, transporte excessivo, movimenta?ao e capital humano mal aproveitado!

Quality issues will end up producing some kind of waste along the value stream (defects, rework). QC could serve as a source of information by which to understand better which are the main quality problems to analyze, find the root cause and execute countermeasures. Team should of course be formed by production and QC poeple among others.

Coordena??o e Colabora??o: Metas claras promovem a coordena??o e a colabora??o entre diferentes departamentos e equipes. Todos trabalham em dire??o a um objetivo comum, o que melhora a sinergia e a eficiência geral da linha de produ??o.

Lean manufacturing is a methodology focused on maximizing value for the customer while minimizing waste. Identifying the value-added product that the customer needs. After value stream the process This means defining all of the steps and related processes that take your product from raw material to final deliverable. Ensure that the production process flows smoothly without interruptions. Produce only what is needed when it is needed, based on customer demand. Continuous improvement in the process up to perfection in the process.

Quality control software must be robust, redundant, and secure against bypassing. It should support fine-tuning and parameter settings through multiple levels of authorization. Additionally, the entire production system should be designed to continuously monitor the QC software, ensuring that no accidental automatic production occurs with any quality checks disabled.

Advanced sensors and software play a crucial role in predictive maintenance by continuously monitoring equipment, processes, and production conditions. By integrating KPIs into these sensors, manufacturers can establish benchmarks and thresholds for optimal operation. When sensor data indicates that these thresholds are about to be breached, predictive analytics can trigger alerts, suggesting maintenance actions or even halting production to prevent the creation of rejects. For instance, if a sensor detects abnormal vibration in a critical machine, the system can analyze the data against predefined KPIs. The system can then automatically adjust the machines operation of shut it down to avoid producing defective products.

Mediante el desarrollo cada vez más específico de software enfocado a la medición de los procesos productivos, se pretende llegar a la perfección. Eliminando muestras fuera de control estadístico o, en todo caso, reduciendo la desviación estándar.

One thing that I have learned in my experience is that many see quality assurance as an after-production step in the entire process. Quality assurance procedures should be scattered along any process. I've seen this implemented in the automotive manufacturing industry but in other industries the micro-quality assurance or quality control procedures that could require more than one department or level of management are not strictly followed. The automotive industry is heavily automated however, so a robot is not going to skip the quality checks it's programmed to perform. One way to get buy in for additional adherence to quality assurance in production is to bring up the robot army waiting in the wings!??????

Mais importante de tudo é treinar constantemente a equipe. Sempre compartilho treinamentos diversos, focados para Qualidade e Indústria. Também é fundamental mantê-los informados, sempre atualizados do que acontece e as propostas é fundamental para o engajamento e colabora??o efetiva. Adoto a prática do "bom dia", todos os dias com minha equipe, momento de 10 a 15 minutos em que repasso o que está sendo estudado, desenvolvido, proposto, e escuto eles em rela??o aos processos de fabrica??o e também suas sugest?es.

Effective training and communication are pivotal for aligning quality control (QC) with production. Ensure your team understands the importance of quality and how their roles impact it. Regular training sessions keep everyone up-to-date with QC standards and procedures. Clear communication channels between QC and production staff facilitate swift responses to quality issues, fostering a collaborative environment where quality is everyone's priority. This comprehensive approach ensures that all team members are well-informed and engaged in maintaining high standards, leading to a cohesive effort towards continuous improvement and superior product quality.

Kaizen ( Kai - continuous, Zen - improvement) is a Japanese word that means change for the better. Organizations often use Kaizen events or workshops to address specific issues and find solutions collaboratively. Continuous improvement is the process of making small and incremental changes to the process rather than waiting for major overhauls, organizations, and individuals continuously seek ways to enhance quality and effectiveness. PDCA(Shewhart cycle) is one of the common frameworks for the Kaizen events Plan: Identify the areas for Kaizen and create a plan Do: Implement the plan Check: Inspect and evaluate the results and compare them with the desired specifications. Act: Adjust the data based on the feedback and Repeat It.

Continuous improvement is the perpetual goal of aligning quality control (QC) with production. By establishing Key Performance Indicators (KPIs) for both quality and production, you can measure progress and identify areas for improvement. Encouraging feedback from frontline staff is crucial, as they often have valuable insights into potential process enhancements. Fostering a culture of continuous improvement ensures that QC and production are not only aligned today but also evolve together over time. This dynamic approach promotes sustained excellence and adaptability, driving ongoing advancements in quality and efficiency.

Alinhar CQ e produ??o é um desafio contínuo que requer um esfor?o coordenado e uma abordagem estruturada. Ao estabelecer KPIs, incentivar o feedback da equipe e promover uma cultura de melhoria contínua, as organiza??es podem garantir que esses dois aspectos cruciais estejam sempre em harmonia, evoluindo juntos e contribuindo para o sucesso a longo prazo.

Antes de qualquer coisa, é essencial entender as prioridades do seu negócio. Em algumas indústrias, a qualidade superior pode ser o diferencial competitivo. Em outras, a rapidez na produ??o pode ser mais valorizada. Estabelecer prioridades claras ajuda a guiar decis?es e a alinhar a equipe em torno de objetivos comuns. O trade-off entre qualidade e produ??o é uma realidade que todas as empresas enfrentam. No entanto, com estratégias bem definidas e uma abordagem proativa, é possível encontrar um equilíbrio que atenda às necessidades do mercado e mantenha a competitividade. Investir em tecnologia, treinamento, metodologias ágeis e uma cultura de melhoria contínua s?o passos fundamentais para alcan?ar esse equilíbrio de forma sustentável.