Last updated on Aug 3, 2024

You're faced with a surge in defective parts on the assembly line. How will you tackle this sudden challenge?

When a spike in defective parts threatens the assembly line's efficiency, quick and effective action is essential. In automotive manufacturing, the quality of components directly impacts vehicle safety and customer satisfaction. A sudden increase in defective parts can be alarming, but it's a challenge that can be managed with a systematic approach. You need to identify the root cause, contain the issue, and implement corrective measures to prevent future occurrences. This article will guide you through the steps necessary to tackle this sudden challenge, ensuring that your production line maintains its standards and your end products remain reliable.

1 Identify Causes

The first step in addressing the surge in defective parts is to identify the root causes. You should conduct a thorough examination of the assembly line processes to pinpoint where the defects are originating. Look for patterns or commonalities among the defective parts. It could be a problem with one of the machines, a particular batch of materials, or even human error. Understanding the source of the issue is crucial for developing an effective strategy to mitigate it.

Add your perspective

Namo V.

Program Manager | New Product Introduction | Quality
Report contribution
Assemble a team close to the process and initiate an IS / IS NOT analysis to identify changes to the system from a known baseline. Systematically document any changes and use process run charts to expedite this process. For example, when weld joints began to exhibit cold joints, the investigation narrowed the issue down to a specific time frame. It was discovered that routine maintenance, specifically the replacement of a welding robot sensor cable, had inadvertently altered the sensor's position, affecting the process. By overlaying critical-to-quality data on a timeline of changes, the organization was able to isolate the issue to a specific weld line and hour of the shift. This allowed them to minimize the impact on the customer.

Like
Karthi M

Assistant Engineer - Supplier Quality Assurance Take responsibility of supplier parts incoming inspection activities and work with the vendor to develop defect-free material supplies!
Report contribution
Defective parts from the assembly line are known as insufficient inspection techniques from the inward inspection ! During the defect parts evaluation, I must first comprehend the problem description and determine the root cause of the case by analysing internal processes or suppliers. After the conclusion, organize a conference with the concerned parties and take permanent action on the case. During the arrangements, any defect-free materials will be replaced.

Like
Artur Pilarski

Senior Engineer PVT at Jaguar Land Rover
Report contribution
Quarantine the deffective parts, involve SPQ team to lease with supplier to inveasigate incomming parts quality, in parallel, basic level 0 to understand if there is influence from the process, request SPQ and logistics team to create a loop for quaranteened parts and increased demand due to rejects.

Like
Jeffery Ritthaler

Automotive Quality Engineer Assembly at TREMEC
Report contribution
1) sort starting line side to feed the operator quality components to keep the line moving. 2) sort all warehouse and shelf stock. 3) collect data from parts serial numbers to provide data for root cause. 4) immediately contact supplier and feed them information to help identify root cause. 5) share feedback from supplier to manufacturing Lead Quality Engineer

Like

2 Contain Defects

Once you've identified where and how the defective parts are entering the assembly line, it's critical to contain the issue. This might involve quarantining the affected parts to prevent them from being used in the production of new vehicles. You should also review your quality control processes to ensure that they are rigorous enough to catch defects. It's important to stop the flow of defective parts as quickly as possible to minimize the impact on the production line and maintain product quality.

Add your perspective

3 Analyze Processes

With the immediate issue contained, you must analyze your manufacturing processes to understand how the defects went undetected. Are there gaps in your inspection procedures? Could your equipment be outdated or in need of maintenance? This analysis should be comprehensive, covering everything from supply chain management to employee training. By scrutinizing each step of the process, you can identify weaknesses and make improvements.

Add your perspective

4 Implement Solutions

Implementing solutions is the next critical step. Based on your analysis, you may need to update machinery, enhance quality control measures, or provide additional training for your staff. It's important to prioritize these changes based on their potential impact and feasibility. Remember, the goal is not only to solve the current problem but also to prevent similar issues in the future. Effective solutions should be sustainable and scalable to adapt to evolving manufacturing demands.

Add your perspective

5 Monitor Results

After implementing solutions, you must closely monitor the results to ensure that they are having the desired effect. Set up a system for tracking the number of defects and regularly review this data. If you notice that the number of defective parts is not decreasing, you may need to revisit your strategy and consider alternative solutions. Continuous monitoring is key to maintaining control over the quality of your assembly line.

Add your perspective

6 Adjust as Needed

The final step is to be prepared to adjust your strategy as needed. The automotive manufacturing industry is dynamic, and what works today may not be effective tomorrow. Stay flexible and be willing to make changes based on new information or changes in technology and industry standards. By being proactive and responsive, you can maintain a high-quality production line that is resilient to challenges such as a surge in defective parts.

Add your perspective

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

Add your perspective

You're faced with a surge in defective parts on the assembly line. How will you tackle this sudden challenge?

1

2

3

4

5

6

7

1 Identify Causes

2 Contain Defects

3 Analyze Processes

4 Implement Solutions

5 Monitor Results

6 Adjust as Needed

7 Here’s what else to consider

Automotive Manufacturing

Rate this article

Thanks for your feedback

More articles on Automotive Manufacturing

More relevant reading