You're up against tight production deadlines. How do you ensure quality control measures aren't compromised?

One thing I have found helpful is the prioritisation of the quality parameters of the product as per Form, Fit and Function. > Identify CTQ i.e. Critical To Quality processes/work stations > Put more resources on CTQs to protect our customers first > Explore Pokayoke/Fail Safe and put interlocks to prevent generation of defects > Create an environment to report the lapses and take corrective actions immediately > Empower the teams to take decisions for resolutions and take ownership

Quality Assurance is more appropriate than Quality Control. Quality assurance can be given by Source control & Process control. Means attack at the point of generation of defects. Objective is to reduce or eliminate the generation of non confirming products. Another aspect is leveraging trained/skilled human resources and deployment of technology. Last but not the least is continuous monitoring. By ensuring these things there will not be any issue in production as far as Quality is concerned.

Processes make or break production shops. In an environment where things are moving fast, everyone “doing their own thing” can spiral into a ten thousand dollar oopsie real quick (ask me how I know). A few things to think about when streamlining: 1. Bottlenecks: a chain is as strong as its weakest link. Whether it’s an issue that requires more people than you have, or simply a bad process, throughput will stall & build up at the bottleneck. 2. Automation: bottlenecks are low hanging fruit for implementing automation. Repetitive tasks in production shops are common, to say the least. Robots & automation can free up more hands than you think. 3. Inventory Management & Lean Manufacturing are things to consider as well.

Na minha experiência, simplificar os processos de fabricação é crucial para garantir qualidade dentro de prazos apertados. Isso envolve a eliminação de etapas desnecessárias e a otimização de todas as partes da operação para máxima eficiência. Adotar procedimentos claros permite que a equipe execute suas tarefas de maneira rápida e precisa, reduzindo confusões que poderiam levar a erros e comprometer a qualidade.

Quando aprendi a mapear os processos , ou seja , ver o fluxo, desenhado alí, pude perceber onde estava o quê e como estava e para onde estava indo, ou se era necessário estar ali. Mapeamento me salvou em muitas vezes, além de excluir de vez, processos desnecessários.

Streamline of processes can contribute to the desirable outcomes. Reduction in line stoppages, breakdown or idle time and frequent change overs or setting up of equipments can also increase the Productivity.

Otimizar processos auxilia na redução de lead time. Com lead times menores, há o favorecimento ou indicador de rapidez da produção.

Na minha experiência, treinar regularmente os funcionários é fundamental para manter a qualidade do controle em momentos de aumento na produção. Investir em capacitação assegura que todos estejam atualizados com as melhores práticas e técnicas mais recentes de controle de qualidade. Isso não apenas reforça a importância dos padrões de qualidade, mas também capacita a equipe a detectar potenciais problemas antes que se tornem erros custosos.

A capacitação, somada a padronização dos processos, permite que haja um ambiente "controlado" nas operações. Conforme os processos são corretamente controlados, medidos, melhorados e padronizados, sua taxa de qualidade se eleva.

Em um mundo em constante mudança e evolução, investir na capacitação e no desenvolvimento dos seus colaboradores se torna crucial para o sucesso do seu negócio. Treinamento de funcionários é um investimento que gera retornos positivos a curto, médio e longo prazo. Ao investir no desenvolvimento do seu capital humano, você estará impulsionando o sucesso do seu negócio e construindo um futuro mais próspero para todos. PREZO E MUITO pelo treinamento das pessoas e em todas as àreas.

Regular training sessions can also be conducted to reinforce the importance of quality standards and provide employees with the necessary skills to uphold them effectively. Additionally, establishing a system of checks and balances within the production process can help catch any deviations from the quality standards early on. Encouraging open communication and feedback channels can also empower employees to raise concerns or suggestions for improvement regarding quality control measures. By prioritizing quality assurance alongside production deadlines, you can maintain high standards of quality while meeting time-sensitive demands, ultimately enhancing customer satisfaction

The training of the team also plays a vital role in defecting free productivity with maximum quality standards. A well trained team keeps your area, equipment and product with less rejections and defects along with least downtime or zero breakdowns.

Automation in manufacturing and quality control can also enhance the productivity, which may always lead to meet the delivery deadlines. Technology can leverage the early detection of defects and flaws in existing systems. Automation can optimize the cycle time and also introduce the new opportunity for more output and productive time to produce and operate and most effective rate.

That’s definitely what helps the most. Unfortunately, although the human being can do fantastic things, when you’re able to create poka-yoke devices (that guarantee error-free activities) or use technology to monitor a critical to quality parameter, you feel safer. Just take into account that this tech will demand maintenance and periodic control so it can be fully reliable.

1. First of all, before accepting the Task, I should plan and ask for the necessary resources, 2. Even after that, If something went wrong by means of resources, "I should know Where I AM" 3. By checking my plan, if I am really doing with backlog, If yes, also the calculate loss in the Brand and Financial. 4. If yes, Plan for Stretching internally extra with out affecting the Quality. 5.Even after the Stretching, if we are not able to attain the Target, Quality with in the Time line, As a Surge Management, Look for 3rd party for the same and debut with Quality manpower to ensure as expected For the future operation, we may plan and decide earlier itself, weather we are going to continue the same or increase our capacity?

Utilizing technology such as machine learning algorithms and real-time monitoring systems can help us identify potential issues early on, allowing for prompt corrective action. Additionally, integrating quality control checkpoints within our digital platforms enables us to track progress, analyze data, and ensure compliance with industry standards. By harnessing the power of technology, we can enhance efficiency, accuracy, and consistency in our production processes, ultimately optimizing our overall performance and output. With a strategic approach to technology integration, we can effectively balance the demands of tight deadlines with the imperative of upholding quality control measures, thereby driving success in our operations.

Utilization of technology like poka yoke system for defective product elimination. Predictive Systems giving early indication for preventing equipment failure and generating defective product

Implementing a robust system where quality checkpoints are integrated throughout the production process can help maintain high standards. By utilizing automated monitoring tools and real-time data analytics, any deviations from quality benchmarks can be promptly identified and addressed. Regular audits and inspections should be conducted to verify compliance with quality standards and to identify areas for improvement. In addition, establishing clear communication channels among team members and stakeholders can facilitate quick resolution of any quality issues that arise.

A condição fundamental para de melhorar algo é que haja a medição do estado atual. Consideremos também que onde não há padrões, não como se medir a melhoria. Então o monitoramento contínuo de processos é obrigação de empresas que buscam a melhoria contínua.

As we know, Safety and Quality should never be compromised. Quality defines brand image. As per QMS, one of the 7 core pillars is customer focus, CSI is metric for that . Customers insisting for IPTV hence Quality has to be built in and should no longer be driven through manual intervention to make sure at least BIQ level 1 maintained, meaning defect shouldn't be passed to customers. For this to happen, lead indicators like PFMEA, DFMEA, Layered audits, SPC audits both Inhouse and at vendors end , MSA audits for gauge R and R, PPAPs any time during product life cycle to be ensured along with digital poka yoke with zero scope for manual intervention and manipulation . Also cost per piece is crucial to maintain quality standards and reward

I personally feel this point is the very first step. Every task is important, but the gravity of urgency with clear communication of the expectations is very crucial to focus on the quantity with quality.

Importante que haja um plano de comunicação, que se desdobre desde o planejamento estratégico até a base produtiva. O conceito de BSC tem como um de seus objetivos a definição da comunicação entre os diversos níveis das organizações, mantendo o alinhamento para os objetivos estratégicos.

La comunicación siempre a sido de mucha importancia en cualquier proceso o actividad. Cuando está se clara, directa y respetuosa puede llegar muy lejos y lo más importante dejar el mensaje. Cuando no es transparente, defectuosa y sin contenido positivo, puede llegar y distorsionar el mensaje en cualquier dirección y hace mucho daño. Se tiene que tener cuidado de la comunicación negativa, por el impacto que puede ocasionar a todos el mensaje enviado.

Why we think quality will be compromised for production first? If we have a good quality system in place with standards, poke yoke, control measures incorporated in the system and checked daily for working against its compliance then why quality will be compromised. Tight production schedules means output ie cycle time is more than takt time or availability of machine / raw material issues. Only improper planning will lead to skip the system and ultimately quality.

Balancing quality control amidst tight deadlines is challenging. Three points to consider : A quality-first culture should be fostered top-down by regularly training teams on best practices and fostering a culture of quality. Allocate additional resources or stretch timelines when really needed, but never cut corners, as it causes a loss of reputation. Leverage technology and efficient testing processes for efficient quality control monitoring for incoming raw materials and outgoing finished products and follow adaptive planning to maintain standards without sacrificing timelines. In B2B manufacturing settings, quality impacts go beyond immediate customers. Tolerance levels should consider the impact throughout the entire value chain.

Develop effective Standard Work. Develop a cultural discipline around everyone following the Standard Work. In the Standard Work is a takt time set to customer demand patterns. Even in a tight deadline, ensure everyone works to the takt time. Don’t speed up. If behind from before and on a tight deadline then need to work overtime. Don’t allow working outside the standard work where all the quality steps should have been embedded.

Ensure that machines / process equipment is well maintained, raw material is qualified and reliable, predictive maintenance, autonomous maintenance are well in place. Provide always alternate plan to production in case if one gets hurdled for some reason, to continue lines and use the time!