Quality Cost Summary Report/Procedure? Cost of Quality

J

joey311

Hi All

Is a quality cost analysis the same thing as a quailty cost summary? I was wondering if someone could provide a link or an example of quality cost analysis report done on a case study, a manufacturing environment or other. I've read about the process on cost of quality and improvement but trying to put into practice i find harder.
I've attached a case study for an example if someone...who can affrod the time, to show me how to approach it, I find examples easier to understand and learn more about the concept.

Cheers guys
 

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antoine.dias

Quite Involved in Discussions
Re: Quality Cost Summary Report/Procedure?

Hi All

Is a quality cost analysis the same thing as a quailty cost summary? I was wondering if someone could provide a link or an example of quality cost analysis report done on a case study, a manufacturing environment or other. I've read about the process on cost of quality and improvement but trying to put into practice i find harder.
I've attached a case study for an example if someone...who can affrod the time, to show me how to approach it, I find examples easier to understand and learn more about the concept.

Cheers guys

Welcome to the cove Joey.

As a starter you may scroll down to the bottom of this page to find 5 similar threads in the cove.
Look into these and if you still need other info I am sure you will get help here.

Best regards,

Antoine
 
S

Sorin

Re: Quality Cost Summary Report/Procedure?

Hi All

Is a quality cost analysis the same thing as a quailty cost summary? I was wondering if someone could provide a link or an example of quality cost analysis report done on a case study, a manufacturing environment or other. I've read about the process on cost of quality and improvement but trying to put into practice i find harder.
I've attached a case study for an example if someone...who can affrod the time, to show me how to approach it, I find examples easier to understand and learn more about the concept.

Cheers guys

1st question: do you have a QMS in place?

If yes...then you should be able to break down each category by defect/cause and so on. Let's take the last part of your summary:

1.Parts scrapped during finishing.
You can look at this and sort by part, by operator, by cause, etc and see if you have trends: if a certain operator is making more (maybe he needs training) / if a part gets more scrapped maybe you need to look at the work technique / if you have a certain cause proeminent maybe there is something wrong in your process / etc.
2.Parts returned by the customer, as scrap.
Once again a question: who decided it was scrap: was it the customer before returning it / your company after return or both were agreeing based on evidence? (this is just my curiosity)
In this case also you can brak it down by cause and look for the trends - also look for customer trend - customer are not always saying that they are not happy.


3.Parts sent back from the finishing section to the moulding shop for rework

1st thing to do is to ensure you have a proper process and proper work techniques - so that everyone working the same step on the same part is working the same way.
Aftre that is the same procedure - look for trends.


4.Parts returned by the customer for rework. See no2

5.Material scrap on the shop floor, mostly in the moulding section.
Same as 3

What scaries me the most is this phrase (see below) and especially the 'guess' part. It sounds like youy don't have a [roper system in place to track your losses.

This might be, at a guess, costing about $35,000 per month.

Also don't be shy and use Pareto as much as you like. This is the most underrated quality tools and it's the one that puts on the fast track when looking to eliminate the big troubles.
 
S

Sorin

Re: Quality Cost Summary Report/Procedure?

I took a little more time and read again the doc. It seems the company does not have someone to drive quality 100% of their worktime. I know that some companies are small and ppl tend to have more tha one hat but if you want to cut down the losses and improve you need that person.
The first thing to do is to lay down work-techniques. Given your domain it's a heaven for visual tecnhiques at any given step of your manufacturing process. Good pictures with indications on the picture can do wonders.
Also lay-daown the causes of your problem. Get the ppl on the floor in the process - they are your best source.
Examples:
deburring - too much
deburring - not enough
cutting edges
air pockets
colour mismatch
etc....

Put in place quarantine zones (waiting for decision and document) and make it a rule that no part or lot can go inside if it's not identified properly (part number, order/traveller number / cause / quantity).

Document all customer complaints. Get after the cost production in order to properly tag your losses (according to manufacturing step where they were scrapped).

Identify your visible and invisible casue of non-quality and use posters like the one I attached (put the company logo, plastify them and put them on the walls - the impact of picture slike that can do wonders).

Do a weekly/monthly quality followup (with management) by departement/causes. Ask for 30 mins every month to meet all the employees and explain what are the causes and how the defects can be avoided.
 

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  • ICEBERG-01-ENG.doc
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S

Sorin

Re: Quality Cost Summary Report/Procedure?

A very simple summary - weekly - you can use it compare from one year to another or to follow the progress of your costs by categories.

N.B. The one that I used was way more complex than that - but it gives an idea.
 

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