Struggling to maintain quality and delivery in automotive parts?

Lean is elimination of waste in short. It is a process and not an event. Before we say we want to eliminate waste, we must be able to see waste. Able to recognize and identify waste is crucial. If the employees don’t recognize waste as what you see, then they will only have the “ask to do” attitude. Hence if they recognize waste then it is only logical to remove it. Lean is also everyone’s responsibility in the whole hierarchy, from the top to the lowest level of employees. Superiors must involve, get engage and not instruct only. Lead by example is key in lean process. Lean is not cutting headcount but making work flow easier for our employees.

Quality mainly depends upon the process and the methodology. First off all their should be good technical sound team should inspect the quality which they actually have pretty good knowledge about the product. This will indirectly reduced the defects by analysis and mainly their should be strict monitoring system on the shopfloor for indentify defects. By using POKA YOKA term we can find the loop hole and set the CAPA for it. This strong mindset has to be implement on shop floor for to reduce the defects.

Due to globally semiconductors shortage, lots of supply chain challenges in logistics. Periodically review of Quality KPI with all quality parameters always beneficial for track quality management system. Conduct internal quality management checks and audits on critical parts and manufacturing processes. Arrange for independent, external audits of suppliers and manufacturers to ensure adherence to quality standards. Implement rigorous batch control and tracking to identify the source of potentially faulty parts. Accurate inventory control of raw materials, parts and finished vehicles Aligning production cycles with consumer demand trend. Forecasting future requirements based on changing marketplace tastes.

Something which is very much overlooked is the act of 'go, look, see'. The actual act of going to a process and watching, understanding and speaking to team members. This will highlight concerns that are not identified on a PFMEA in an office environment. You may even find that a quality problem could have been contained and countermeasure by a simple check from a member who is unaware of the concern.

In my experience one has to identify problem areas for low quality first. Review data and evaluate if data is providing real problems with acceptable accuracy. Update data collection if needs improvement. Establish gates for quality data. Review data and identify $ impact of quality. Do a Kaizen event to address high loss area. Evaluate impact/improvement. Repeat cycle

La calidad no es una opción, debe ser parte de todo proceso de fabricación, asegurar que cada proceso se lleve a cabo como fué diseñado y las pruebas de cada componente, asegura tener una producto final casi infalible. Un proceso continuo y robusto, siempre debe tener un control de calidad minucioso y ser revisado en los puntos de inflexión.

Quality is the key to having a succesful business. More often than not companies forget the importance of considering the cost of quality. I see many companies struggle in the long run because they were not able to setup robust quality systems and build quality into their products.

Always make the suppliers distinctly different in materials controls systems for traceability. If you have a warranty claim, you need to know which components were from which supplier. Make the tool identified through a mold or casting variation or unique symbol that can be recognized from their PPAP part. Lesson learned from previous experience.

Suppliers and manufacturers are partners in achieving success, effective and capable supplier is initial step to produce product matches quality specification and customers demand

El desarrollo de proveedores es parte crucial del proceso de fabricación de autos. No solo es una relación comercial, se debe conocer cada detalle de los procesos, equipos, maquinaría, gente y sobre todo los planes alternativos de continencia. Trabajar de la mano con cada uno de ellos, para tener un plan de auditorías, garantiza el 99% de éxito.

Suppliers play an important role in our supply chain. Maintaing a healthy and cooperative relationship with them can make us or break us. Having open and honest lines of communication allows suppliers to feel they are part of the team. As SQEs we need to develop our suppliers to make them understand that we are here to ensure they are successful. Their success in delivery quality parts we will allow us to continue building the best quality cars for our customers.

Create an environment where your people are encouraged to offer their suggestions and ideas. Managing from the bleachers and not knowing your people is ineffective

The use of advanced technologies of production like robotic and automotion can help us and is very important for to get the process estandarization

Mi recomendación es tener una revisión periódica del papeo de proceso, dependiendo de la necesidad de Fabricación y las partes a desarrollar, hoy la tecnología esta muy accesible para poder implementar mejoras en los procesos, monitoreo del hxh de cada área. Sin duda la robótica va ser utilizada cada vez con mas necesidad de mejorar la precisión y calidad de los productos.

El capital de trabajo como es conocido en otras industrias, es la parte fundamental del proceso que va ligado de la planeación de la demanda, el forecast y el Budget de la compañía La certeza del lead time y tiempos de fabricación, disponibilidad de materias primas. Tener inventarios sanos y un IRA preciso acompañado de inventarios cíclicos. Da la certidumbre de cumplir con los requisitos del cliente en tiempo, forma y cantidad.

Embracing Continuous Improvement (CI) can be the game-changer. By consistently evaluating and enhancing processes, we can reduce defects, streamline workflows, and ensure timely deliveries. Techniques like Six Sigma, Control charts, Kaizen, and Lean methodologies help identify inefficiencies and implement effective solutions. Let's drive excellence and reliability in our automotive supply chain through the power of CI!

"Success is the sum of small efforts, repeated day in and day out. " The key to continuous improvement is making small significant improvements everyday.

In my years in quality there has been many programs attempting to stream line manufacturing. But no one follows through they re-word the process and call it a new program approach. The tools are the tools focus on those and the program will take care of its self.

If you are having a moment and feel like you can’t control your emotions, don’t ever take it out on your team. If you don’t want to make your best people stop working for you, at record speed, then don’t take your personal emotions out on them. If necessary, remove yourself from the situation until you feel you can act professionally