WHY "COPQ" was so HIGH ??

This case study was conducted by me for a well known & very positive SME, very recently and following potential/probable causes listed out during "BRAINSTORMING" session:

• "5S" not implemented as a habit.
• "KRA" not defined for all.
• "Scrap" disposal is not being done on time.
• "QUALITY POLICY" not understood by all employees in an intended manner.
• "Quality system procedures" made by one person of the company.
• Inadequate, incorrect control plans & checkpoints.
• "CUSTOMER NEEDS" & requirements not captured completely & perfectly and even not addressed in the control plan.
• "WORK INSTRUCTIONS" are made in English & those are not well understood by workmen.
• "OVER PRODUCTION" / Unwanted productions.
• "INADEQUATE" relevant training.
• Training identification is done without the involvement of employees.
• "DEMOTIVATED" employees.
• "ABSENCE " of basic infrastructures.
• "TESTING FACILITIES" treated as cost addition in budgeting.
• "PREVENTIVE MAINTENANCE" mostly missing.
• "FMEA" not being conducted as proactive improvement tools, but treated as a showcase to customers.
• Inadequate FMEA training due to lack of internal trainers.
• "SPC" is not being done honestly.
• "PPAP" records are not being treated as for the purpose of internal improvements.
• "ECNs" are not being effectively monitored for effectiveness.
• No "KAIZEN" culture in the company.
• No "QCC" exercise, team formation , project selection,implementation & celebration.
• Problem-solving techniques are not being used by the team.
• Lack of honest "CALIBRATIONS".
• "CAPA" is not being made because root cause identification exercise is not being done. Everything on the past experience basis.
• CAPA is treated as customer's satisfaction normal paper, not as a business project.
• "RPN" numbers & it's reduction methodology is not clearly understood by all group members.
• Real "OEE" calculation is missing in the system.
• More numbers of non-value added meetings are conducted by top management.
• " DESIGN CHANGES" are not updated timely.
• "OBSOLETE" items &documents are not being disposed of on time.
• "CUSTOMER's APPROVAL" are missing in many cases.
• "NO ROUTE CARD" is being implemented for FIFO.
• Inadequate product identification & traceability starting from receipt of RM to product dispatches.
• Standardisation is missing.
• "SOPs" are not made for all processes.
• SOPs are not in local language & not adequate too.
• " POKA-YOKE: not implemented at critical operation, where monotonous work is going on.
•  By-passing of Poka-yoke by operators & no actions by the supervisor.
• A shortcut in operations. One operation bypassed to meet the production quantity.
• Very low numbers of low-cost automation( LCA).
• VALUE STREAM mapping training is missing.
• Deskilling/ multitasking not being done as a system requirement.
• Rejection/rework is treated as a continuous improvement project.
• Detail MIS review is missing.
• TOOL HISTORY CARD is not being filled honestly by tool room in charge.
• High fluctuations of voltage in summer & no proactive actions are taken.
• Bad quality water is being used in the process.
• No accurate & proper temperature control mechanism is being implemented.
• Machines are working without chiller even in summer.
• Without looking at output quality of the product, Cycle time reduced to get maximum output.
• TPM is missing on the machine.
• No pre-training to contract labor ( new entrants).
• Fear of job security at all level of a hierarchy.
• Incapable of PPC/ wrong production planning.
• Very poor material handling mechanism.
• Very poor storage system.
• FIFO concept & implementation is missing.
• Unwanted cost-saving actions.
• ILL/ negative minded employees.
• Many employees having their own family problem & always in a disturbed mind.
• Applying less operation time than really required ( Less time, less temperature, less pressure, higher RPM)
• Constant mental pressure due to extra work.
• Operations at an old machine by old & obsolete technology.
• Management wanted a cheaper solution by neglecting the required quality.
• Incapable supervisor( Low qualification, no training & low skill level).
• Known malfunctioning by negatively minded employees.
• Use of known inferior quality of RM.
• Improper mold/does design (Location/ centering/ovality/perpendicularity/parallelism/flatness)
• Not on time & wrong mold/dies maintenance.
• Wrong loading & unloading method
• Monotonous & manual working by the same operator for many months/years.
• Wrong packing &packaging design.
• Wrong & unsafe transportation method.
• Higher dust & moisture level.
• Faulty control setting.
• Quality approval on experience basis, not proper tools & techniques used for that.
• To meet the delivery quantity, faulty materials mixed with an ok material ( Knowingly).
• Poor capability supplier ( Approval based on reference & good nature, not at good system basis).
• Improper process parameters used ( Speed, feed, pressure, temperature).
• Initial setting is done by untrained people, not by an expert/ experienced people.
• Improper rework methods used for rectification,
• Use of less cooling & settling time.
• Operators negligence( known/ aware but not done correctly due to some extra efforts required).
• Improper mixing of raw material, paints
• Known dual standards quality of same products ( Only for market application, only for OEM applications)
• Processing of slow-moving stocks without verification of quality.
• Misunderstanding due to puzzle mind.
• old standards used due to lack of correct information at the department level.
• Machine capability low.
• Due to the bad relationship between two contractors.
• No patrol inspection at night.
• Low capability supervisor's deployment at night shift.
• Poor operation layout( Zig-zag)
• Poor line balancing/ batch production.
• Improper cleaning of working surface ( Chips/ swarf accumulations).
• Excessive tightening/ lose clamping.
• Mixing of foreign material( Rubber mixed with the metal particle, Aluminium mixed with brass)
• Fallen material kept with the ok material without visual inspection.
• Wrong sampling plan used for inconsistent supplier
• Wrong measuring method( Attribute checking for the Variable i.e surface finish checking by visual method)