Problemas de controle de qualidade assombram sua linha de montagem automotiva. Como você pode evitá-los de erros humanos?

Trainning man power and making the clear task for each step 1. Making visual sample OK and NOK 2. Making GO no GO 3. Consistance sequence

Para alcançarmos a alta performance de um processo produtivo, os treinamentos são de extrema importância, mas um detalhe que muitos gestores deixam passar despercebidos, o foco nos treinamentos tem que visar a mudança de comportamentos do seu time vencendo as resistências, que é um comportamento normal do ser humano. A grande pergunta é: Como lidar com a resistência à mudanças? Comece ajustando o TIME aos novos padrões, de acordo com o plano de mudança e aos objetivos trabalhando o empowerment do seu time!

1. Training manpower and making clear task for each step 2. Making visual sample 3. Implement standardized Work Instruction (SOP) , updated control plan , process flow chart ans Pfmea

Trainings are important but it is not possible to avoid the errors/mistakes/defects only by providing extensive trainings to the teams. The work standardization and error proofing are the other available options. Make the assembly process as visually interactive as possible. Use the following options of error proofing; A) Prevention of Errors. To achieve this, the risk involved in the process needs to be identified, quantified and mitigated. Use tools like "Process Failure Mode & Effect Analysis" for this purpose. B) Detection of Errors: The knowledge learnt while implementing the FMEA will be helpful to map the current/newly required controls in the process. C) Elimination of the Errors: Use GO OR NO GO techniques for this purpose.

Tailoring training programs to specific job roles can boost precision. For instance, operators, inspectors, and supervisors should each receive training that aligns with their responsibilities in the quality control chain. Encouraging employees to provide feedback on the training programs can identify areas where gaps in knowledge still exist, which can then be addressed in future sessions. Additionally, involving workers in identifying common sources of errors helps in reinforcing lessons learned during training.

Nem todas as empresas tem capital para investir em tecnologia para inspeção da qualidade, uma ação simples e muito eficaz, é investir na capacitação do colaborador e dar as melhores condições para que ele possa executar as suas atividades, e principalmente, dar autonomia para que o mesmo possa parar o processo, caso ele identifique alguma anormalidade, seja do equipamento ou da matéria prima que possa afetar a qualidade final do produto.

Vision System/Automated Inspection Systems are very effective and efficient. The chances of human errors can be minimized by using such kind of systems but it has its own challenges as well. It vision systems required a lot of data ( qualitative/quantitative) in order to learn the decision criteria. It becomes even quite difficult to make the system learn which there are quick change overs. The 2nd challenge is the system calibration itself. If above stated challenges are dealt accurately, then the vision systems can be a great option to minimize the inspection errors.

Incorporating technology to minimize human error is essential in an automotive assembly line. Automated inspection tools, such as vision systems, can detect defects with a level of speed and precision unattainable by manual inspection. Additionally, error-proofing mechanisms like sensors and smart fixtures prevent common mistakes during the assembly process, ensuring higher accuracy. These systems not only help catch issues before they escalate into costly problems but also lighten the cognitive load on workers, allowing them to focus on more complex tasks. Integrating such technologies promotes consistency and reliability, ultimately driving improvements in product quality and operational efficiency.

A healthy culture which promotes the continuous improvement is the key to the success. It can be achieved by extensive counselling and making the quality KPIs a part of the performance system of all employees. The continues improvement initiative can never be successful without a well integrated and aligned reward system including both the financial and non-financial rewards.

Building a culture that prioritizes quality and accountability is key to reducing human error on the assembly line. Promote open communication so that every team member feels empowered to raise concerns and suggest improvements. By fostering a no-blame environment where mistakes are seen as learning opportunities, you create a workplace that values continuous improvement rather than simply focusing on speed. Encouraging ownership of the final product at every level ensures that employees take pride in their contributions. Regularly recognizing and rewarding those who consistently uphold or exceed quality standards helps reinforce the importance of maintaining high performance, motivating others to follow suit.

Visando um fortalecimento de um processo produtivo é essencial investir na criação de uma cultura, a partir da alta gestão, a cultura da melhoria contínua, onde todos possam contribuir, independente do retorno financeiro que ela venha a proporcionar. Mas é muito importante o direcionamento para a eliminação e/ou redução dos 7 desperdícios (Excesso de produção; Transporte; Estoque; Espera; Excesso de processo; retrabalho; excesso de movimentação) potencializando o conhecimento do seu time com foco no que agrega valor ao produto final.

Currently in RSA all communication is in English! In a province like Gauteng the important facts get lost! At least two other dominant languages must be used in all Provinces!

Train your team on lean six sigma tools like kaizen, quality circles, Gemba walks, value stream mapping, process capability analysis, measurement system analysis and control charts. All stated tools when properly implemented, will result in stable manufacturing processes that can resist the failures/errors/mistakes.

Para trabalharmos com Revisão de Processo, é muito importante o Gestor realizar o Genchi Genbutsu (lugar onde as coisas acontecem) e seguir as sequências para análise de processo: 1) Classificação de cada etapa, identificando o que agrega valor (Shomi), o que não agrega valor mas é necessário (Fuzui) e o que não agrega valor (Muda); 2) Atacar imediatamente os problemas de sobrecarga tanto dos equipamentos e principalmente dos colaboradores (Muri); 3) Trabalhar para eliminar as Variações (Mura) 4) Trabalhar para eliminar as atividades que não agrega valor (Mudas); 5) Trabalhar para reduzir ao máximo as atividades que não agregam valor mas são necessárias (Fuzui).

Regular process reviews are essential for identifying areas where human error is likely to occur and for implementing targeted improvements. By thoroughly mapping each step of the assembly line, you can pinpoint high-risk stages and introduce measures to mitigate errors. Continuous improvement methodologies like Six Sigma or Kaizen can play a crucial role in systematically addressing these issues, helping to reduce defects and enhance overall quality. Additionally, these reviews offer the chance to gather insights from employees, who often have a firsthand understanding of inefficiencies and potential process optimizations. This collaborative approach ensures ongoing refinement and a more resilient production system.

In order to analyze the errors, the data collection is the key. Make sure to collect the data in proper way. Avoid measurement errors ( gauge and appraiser errors). For this purpose, use Gage R&R Studies and Attribute Agreement Analysis to minimize the gage and appraiser errors respectively. Furthermore, while collecting the data, use the correct sampling technique. The Proportionate Random Sampling and the Cluster Sampling both are widely used techniques. Once the data is collected, then analyze the errors by following the below steps; A) Use "Preto Charts" to priorities the action plan on the errors. Consider the both; significance and frequency of the defects B) Then use tools like "DOE, Why Why Analysis, Cause & Effect Diagrams.

When errors occur, conducting a thorough error analysis is key to preventing them from happening again. Root cause analysis allows you to look beyond the immediate mistake, examining deeper factors within systems and processes that may have contributed to the issue. This approach helps identify underlying problems, such as equipment malfunctions, inadequate training, or unclear procedures, that may not be obvious at first glance. By addressing these root causes, you can implement corrective actions that lead to lasting improvements in quality control and reduce the likelihood of similar errors occurring in the future.