You're striving for high quality in production. How can you increase output without sacrificing standards?

Lean principles are effective in ensuring productivity. To enable smooth implementation and compliance to lean principles the 4M in manufacturing should be maintained at standard (Man, Machine, Material & Method). An effective approach to ensure the effectiveness of 4M and for a reliable factory or process the best tool in my view is TPM. TPM (Total Productive Maintenance) ensures that the input to the process is in compliance with standards set for the best output. When inputs are at its best the productivity will also go up. Measurement and addressing of losses (16 major losses) improves OEE and this is reflected as increased productivity.

You already studied your market, you already take the values os the costumers on the piroducts, you know the standart os the quality on the comosnie and the level os the quality that your costumers demand, you have to use the quality tools in order to keep makinh the quality keep on the standarts that you set on the plann. It¨s also important to monitor progress os the quality with the quality indicator, you have to set the best KPIs, in order to do that. Thanks, Linkedin.

Utilising SPC throughout the process to understand any sort of tool wear or machine variation would be vital. If these are in place and the people surrounding the process understand how SPC can help them, I've found that processes that need significant ramp up as project gates get crossed can almost look after themselves once a robust SPC process is in place.

I agree with the prospective of automation technology. This will produce rigorous & realistic results and consistent productivity because there is no probability of human error and process variance. Only we need to perform systemic validation for these automated processes at a definite time interval. This technology has more reliability as compared with any traditional methods. e.g. In case of visual inspection process of pharmaceutical injectable units, we can use automated process because manual method requires human visual inspectors, who sometimes perform inadequate inspection (deliberately / unintentionally). While a machine will produce only accurate and similar results. Hence, automated technology is considered as best suitable.

To ensure quality doesn't suffer during increased production output, two key tools are used: Statistical Process Control (SPC) and Failure Mode and Effects Analysis (FMEA). **SPC:** Monitors production processes in real-time, detecting deviations from the norm, allowing for early problem-solving and reduced risk of defects. **FMEA:** Anticipates potential failures, identifying potential problems and implementing corrective actions to minimize defects and improve overall product quality. This will leads to Reduce the risk of quality issues and Increase the efficiency and cost savings By incorporating these tools into your quality management system, you can maintain high standards even with increased production volumes.

IATF16949:2016 covers the process of identifying the risks and evaluating the potential of the impact that could occur due to those risks. It also designs the strategies to mitigate such risks by analyzing them. RFMEA is the method to review the PFMEA using on-site or shop floor observation. In this method, the organizations should check their existing FMEA with actual shop floor process and improve it by identifying new failures and their corrective and preventive actions. QRCI, or “Quick Response, Continuous Improvement” approach which focuses on a more holistic manufacturing practice.? It is a system of different stages that allow managers and product owners to better respond to issues arising from a production line.