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.