Você está enfrentando um aumento de defeitos na linha de montagem. Como você abordará e resolverá esse problema rapidamente?

In my opinion and experience, a visit to the actual workplace where the surge of defects is being reported to have an understanding of the assembly process and engage with the frontline operators, and gain insights. Once we have a deep connection with frontline operators, then we can use RCA and 5 Whys to find an effective problem solving to make a strategic decision to empower people to be problem solvers.

One approach I found helpful is to broadly categorize the defects/issues into a simple Pareto chart to identify the main contributors. Following this, conducting a GEMBA walk can provide valuable insights into the issues and the process. When performing a root cause analysis or developing corrective actions, it is crucial to involve the people and operators directly affected by the issue. Their input is essential for ensuring that the corrective actions are sustainable.

Go look see is vital, I have seen even experienced quality engineers do the root causa analysis from their desks, it leads to invalid is/isnot analysis and they endup solving the wrong problem. Meanwhile the organisation continues to lose revenue and possibly reputation. if you don't stop what you are doing and go straight to the shop floor immediately then you're doing it wrong!

“Walk the process” some problems are obvious. If it is not “assemble your team” agree the “problem statement” implement an “8d” process, if you have one. Above all “PROTECT THE CUSTOMER”

A process audit is like doing an MPR (Manufacturing Process Review) where you can identify all your inputs, the process, your output and possible failure modes.

I fail to understand why a process audit is not part of determining the corrective action. Walking the process and documentation is key to understanding the root cause. This documentation may be updated based upon determining the root cause as well as the corrective action that ensues.

A proces. S audit is one of the quickest ways to start with the input, look at the process and output(s). It gives you more than just a process overview, it also gives you a quick glance into what's coming from the internal supplier and moving to your internal customer, or external customer.

I am not involved in a quality role within my work place, however I do believe using good common sense is always the way to go. First step is to stop production. Do not carry on wasting money and employees valuable time in producing components you know will be defective. I would then gather evidence of documentation and settings from the last batch of good product inspected and passed, then check it against defective batch documentation and settings. Something has changed?. If you have a trouble shooting guide in place check that. This may be a recurrence of a previous fault. Use your evidence gathered to have a brain storming session with those who know the process, equipment, and machinery.

I would be very specific and audit at least 10 action production orders versus documented process to see if a trend is shown.

Introducing additional checks is a short term control. Where possible, true poke yoke and/or red rabbits need to be implemented to ensure resolution. Further, update PFMEA and Control Plans to ensure read across for future projects.

Increase audit frequency after ca to ensure through sampling you have properly solved the problem then relax you outgoing inspection crteria

I find this is an area that is frequently neglected. We often rush to find a root cause, then fail to monitor adequately to ensure the issue is truly resolved. Clearly, the method will vary depending on the root cause; however, this step is crucial in determining efficacy.

L'amélioration continue fait partie des principes de la normes ISO 9001 et de la roue de Deming ( PDCA). L'amélioration continue permet d'atteindre l'excellence opérationnel

Ensure continuous improvement by implementing baseline PFMEA and Control Plan by similar product lines. Always attempt to start any project with the latest and greatest documents available ensuring lessons learned are captured.