Sua linha de montagem está comprometida por materiais abaixo da média. Como você garantirá que os padrões de qualidade sejam atendidos?

Hmmm… This is CoQ… Cost of Quality. The intended quality still could be ensured, but: - This needs additional deployment of resources at incoming stages. - This involves cost of scrapping subpar materials. (still preferred before processing) - This may affect “Brand Quality” as it deteriorates the image when customers use substandard end product. - This increases rework costs overall (detection, correction, presentation) As I mentioned, can be ensured but it costs and that’s CoQ!

Rework or replace subpar materials Implement quality control checks Conduct regular inspections Train staff on quality standards Source materials from trusted suppliers Test materials before assembly Implement corrective actions promptly By taking these steps, you can ensure quality standards are met despite subpar materials initially being used.

“Assy line is already compromised!” 8D: - Define and describe the problem. - Identify the impact (how many parts, how late, how much will it cost). - Implement containment actions in order to assure production and keep the business running (replace parts, rework, additional inspection, etc). - Identify Root Causes - Define corrective actions and plan them. - Implement and control traceability of the improvement. - Extend actions to similar products and/or processes (Including update of all Process documentation) - Recognize the team once all done!

It all starts from initial engagement with suppliers. Contractual terms, compensation, penalties (both ways), rewards, supply terms (deliveries, scheduling)… In the event of subpar deliveries by suppliers, it is advisable that “SoP” is already existing to handle it. Then there is no ambiguity or room for ulterior motives. Nevertheless, immediate measures could be: - Mutual agreement on issue on hand - Quick measures to mitigate situation - Sharing of consequences till the formal understanding is reached. And of course, installing preventative measures is utmost important to avoid recurrence!

Everything is possible but subpar material calls for additional deployment of resources in terms of money, manpower, time, space and and and… Ensuring quality in such situation calls for: - Segregation of good and bad parts - This will need adapting line line / storage area layouts - adding check stations in lines need to be installed (resources!) - Checks on already built products to eliminate miss out! - Final check with specially designed check sheets and trained resources. Adapting process quickly to mitigate situation is the key. And yes deriving “preventative measures” should be the intent.

Process adjustment for subpar materials: Implement stringent incoming inspections, reject defective materials, and collaborate with suppliers for quality improvement. Enhance worker training on defect identification. Monitor production closely, adjust assembly processes as needed, and consider alternative suppliers if issues persist.

Stop production*: Immediately halt production to prevent further use of subpar materials. *Inspect inventory*: Inspect the entire inventory of materials to identify and isolate subpar materials. Source replacement materials*: Quickly source high-quality replacement materials from trusted suppliers. *Conduct quality control checks*: Implement additional quality control checks to ensure the new materials meet standards. Rework or scrap*: Rework or scrap any products already assembled with subpar materials. Train staff*: Educate staff on the importance of quality materials and the procedures for identifying and addressing subpar materials. *Review supplier contracts*: Review contracts with suppliers

Staff training should focus on: 1. Material identification & inspection: Teach workers to recognize subpar materials, understand quality standards, and perform thorough inspections. 2. Problem-solving & reporting: Equip staff to identify issues, communicate problems effectively, and suggest solutions for improvement. 3. Quality control processes: Train workers on quality control steps, documentation, and the importance of adhering to standards. 4. Continuous improvement: Foster a culture where employees are encouraged to suggest enhancements and participate in quality improvement initiatives.

To prevent future material issues, implement rigorous supplier audits, strengthen quality control checkpoints, and invest in advanced material inspection technology. Diversify suppliers to mitigate risks. Foster strong supplier relationships for open communication and timely issue resolution. Continuously monitor and analyze quality data to identify trends and take corrective actions.