I suggest you start by identifying your major scrap items/categories/costs (Pareto)
Pick out the ones that are causing you the most problems and form problem solving teams.
Use tools such as brainstorming & cause & effect analysis to follow a systematic approach.Run tests & evaluate the results before deciding upon solutions. Implement the best solutions & standardise your improvements- watch the costs go down.

Sounds very easy, in practice it's hard work but the results gained are worth it(stick at it!).

If you're not familiar with things like the 7 QC tools or the PDSA cycle, it's important to invest time in training & education before you start trying to trackle the problems.

I'm co-ordinating several scrap reduction teams at the moment, if you need any advice feel free to drop me an e-mail.

We Were Told By Our Outside Auditor That We Had To Come Up With A Prioritized Action Plan To Reduce Scrap. How Do We Do This? I Don`t Know Where To Begin. Please Help..

Originally posted by Don Watt:
If you're not familiar with things like the 7 QC tools or the PDSA cycle, it's important to invest time in training & education before you start trying to trackle the problems.

I'm co-ordinating several scrap reduction teams at the moment, if you need any advice feel free to drop me an e-mail.

Don (or anyone else):

I am doing similar here. I am training 6 people to be the future team leaders in the company. Question: I know PDCA, 7 QC, etc., myself and am in the process of teaching them to others. Have you found any good resources that are "ready-made" training sources? I don't want to spend time inventing my own if there are good ones already available.

Thanks for you help.

I haven't come across too many "off the shelf" resources, although one reasonably good commercial resource can be found at www.tqmi.co.uk (http://www.tqmi.co.uk)

If you browse the pdf files on this site, there's somem very good stuff there e.g. 8D-A.pdf for structured problem solving.

I'm originally from a training background and I tend to prefer to develop my own stuff.
I believe I've got some materials on the 7QC tools + PDSA etc. archived on disk - I'll have a peep through, see what I can find and get back to the forum.

TTFN

The "Juran Institute" offers an excellent training course for teaching quality improvement tools and technology.

I collect the number and style of defect parts every month.analyse it with parateo chart to find the biggest problem.

at regular quality meeting every month, i will propose this chart and every one at the meeting analyse the main cause as they think about it.then a team leader which department is related is assigned to gather his team for analysis further and propose their action plan to solve the issue. I am the coordinator if they need help.when the action is finished, I will verify its effectiveness and then close it if the result really meet the goal made at the meeting.
similar as 8-d.

all the documented package are PRIORITIZED ACTION PLAN every month.

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[This message has been edited by hawson (edited 08 November 2000).]