Você está enfrentando um aumento no número de peças defeituosas na linha de montagem. Como você vai enfrentar esse desafio repentino?

Formation of cross functional team as per the defective parts is one the major aspect of analysis of issues. After that the entire team should note the problem definition of occurring defectives online using 5W1H or 5W2H method. Now once problems are defined using a defined tool, then a containment actions should be planned accordingly to first contain the problem at the defined zone So that it will not flow further. After that stratification of defectives using bar chart, stacked column chart, Pareto analysis tools to prioritize defectives which must be addressed at beginning severity or occurrence. This data can be easily retrieved from past trouble data sheets. Once we have data we will use an analysis tool to identify the root cause

Depending on the defect. You can narrow down the stations, or equipment that have an effect on that damaged / defective parts. There is generally no need to review the entire process. Generally it can be narrowed down fairly quickly. Once the area in production has been identified, identify if its equipment caused or operator. If it’s equipment based, maintenance and calibration may be necessary. If it comes to personnel, a change in training, tools, or processes may be needed. In any situation avoid over reacting and changing too much. You can bury root causes without identifying them.

Once we have stratified our data and we have significant defectives for which we have to use analysis tools for RCA. For RCA we should use the funnel down tool which is first we should identify all possible causes for the particular defect in our process starting from the incoming inspection station to the final dispatch station for this we have a control plan for it. Based on soft controls and hard controls in process we have to list down potential causes. If the supplier is a potential source then we will immediately raise NCP to the supplier in which complaint details along with complaint sample must be sent and obtain a SCAR from them using analysis tools such as 8D, A3 report. Audit should be followed with that at supplier end.

Engaging with suppliers can become more effective when we implement and upgrade their QMS as per our own standard or quality system requirement. For this we have to train and develop the people working at suppliers. One such example is Doujo room a small training centre in which different functional aspects are covered effectively. Supplier rating measuring and monitoring on a monthly basis based on their quality, delivery performance and response. Supplier audits are also one of the most effective ways of fact finding at supplier end related to their QMS, product and process. Encouraging our suppliers to promote automation in their process to eliminate the man dependent errors and robustness of their process.

All of this is of great complexity, if one goes into assembly then the problem can be solved for some time because as we are seeing today, time is of great importance and if the assembler is experienced then he can find a solution for it as I am saying, time is important here, full responsibility of quality is formed, 100 percent inspection so that the joining links keep moving.