You're facing quality control issues in Lean Manufacturing. How can you tackle them effectively?

In one of my last assignments we suddenly faced a very big increase in quality defects on a certain productline. Using the RCA method pointed out that some new employees and operators did not have adequate training. With an extra quality control program we could eliminate these defects immediately. Afterwards the training program was reviewed to prevent recurrency. RCA is simple, fast and effective.

Quando tomamos a??es com base em metodologias consolidadas da literatura, a chance de sucesso é alta, independente da metodologia utilizada. O que difere qual metodologia deve ser aplicada é o grau de maturidade da empresa, visto que algumas metodologias ser?o mais difíceis de transmitir à equipe. Contudo, se aplicarmos um simples "5 porquês" ou o próprio diagrama de espinha de peixe, a análise de causa raiz estará perfeitamente embasada e seu problema pode ser rapidamente solucionado.

Do the Root cause analysis. Find out the possible causes which contribute to the quality defects. Do the brainstorming session with CFT and list down the appropriate corrective action and try to find a foolproof or mistake proofing solution. Next step is to implement the corrective action and ensure its Effectivity and random audit to check corrective action is being followed or not. Then next do the effectiveness check.

RCA and Process standardization with Dashboard review of control parameters daily basis will ensure elimination of defects and to meet product functionality

To tackle quality control issues in Lean Manufacturing effectively, 1. Implement Continuous Improvement (Kaizen): Regularly identify and address inefficiencies and defects in the production process through small, incremental changes.

Training is wasted unless it is delivered "Just-In-Time" for a specific purpose. Resist the temptation to train everyone unless they will be using the skills soon. 1) Acquaint the team with the RCA team approach and specific approach to solving the problem. Review the problem statement and objective. 2) Training on how to read reports describing the problem may be required. What is the data trying to tell us? 3) Training on Lean tools may be required. 5S and Standard Work are great places to start to eliminate issues in the workspace. Flow and Setup Reduction are great secondary topics. 4) Specific skills training may be required: ** Quick tool change techniques in a machine shop, ** Spaghetti diagram for laying out a work area YMMV

2. Use Root Cause Analysis: Apply tools like the 5 Whys or Fishbone Diagram to identify the underlying causes of quality issues and develop targeted solutions.

Factory floor workers need continuous training to better understand the product and its utility. If an operator does not recognize the impact of their work and the consequences of non-compliance, it is not fair to hold them accountable for it.

3. Standardize Work Processes: Ensure that all tasks are clearly defined, documented, and consistently followed to minimize variability and errors.

Gather people who do the same job and watch one person perform the job and discuss the result. You'll find that people often have different approaches to tasks and the best method is a combination of everyone's discoveries. Make it clear to the team that the purpose is to find the best method of completing the job, not rewarding or punishing based on individual performance. Experiment and try different ways to improve the 4 pillars, Safety, Quality, Delivery, and Cost associated with the job. Train others using EDGE: Explain, Demonstrate, Guide, Enable so people know how to do the job properly, and what to do when the job is not correct.

Standardizing processes can be a time-consuming and detailed task, as it requires a thorough understanding of each step to ensure the documentation is clear and precise. However, when a non-compliance issue arises, identifying the 'outlier' becomes quicker and more intuitive.

Provide opportunities for employees to work "on" the business, not just "in" the business. Some companies provide time daily or weekly for individuals and teams to work on improvements using a mantra of "Fix What Bugs You." This drives regular improvement activities. The 2-Second Lean approach, developed by Paul Akers is an effective method to get people to think about making at least one 2-second improvement in their work areas every day. The result is that people are constantly thinking about how to improve the job.

4. Focus on Employee Training: Provide ongoing training to employees to enhance their skills and understanding of Lean principles, ensuring they can spot and address quality issues promptly.

No process is so bad that it cannot be improved, nor so good that it cannot be enhanced. Continuous improvement lies in both large and small changes, and believe it or not, many overlook the small ones, which often yield excellent results.

What is wrong with what .. Que estamos haciendo mal o ha tenido un outlier por ese defecto. También se verificó el PFMEA ? Causa especial ?