Inspecting Quality into Product - How to react?

RoxaneB

Super Moderator
Super Moderator
#11
Re: How to react? Inspecting Quality into Product

In such a case, you can only tighten your inspection. Make it tighter than your customer. Any rejects should get held inhouse. Reject complete lots like your customer does. Dont reject pieces. Let a few deliveries be missed.
Tightening inspection is a correction and will not help the situtation in the long-term; it does not address the root cause which could lie in any of the following areas (if not others):
  • Production - making defective parts
  • Engineering - defects designed into parts/processes
  • Receiving - not noticing poor incoming supplies (garbage in = garbage out)

Missing deliveries?!?! :mg: Why do you suggest this? So now the Original Poster's organization is still making bad parts and the Customer continues to be unhappy (just for a different reason).

I agree that tightening the inspection might help out in the short-term, but this situation requires a much deeper analysis to develop a truely effective action plan.
 
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Wes Bucey

Quite Involved in Discussions
#12
Re: How to react? Inspecting Quality into Product

I am always frustrated when I read a thread like this where the organization in question is still in denial over the value of the concept:
"It is more economic to prevent rather than detect nonconformance."

The fear for the organization managers should be that the customer will become angry at the inability of supplier to provide defect free product.

The customer is obviously nearly as clueless as the supplier managers because they are still content to eat up their own soft costs of inspection instead of demanding a corrective action from the supplier.

This is not a simple fix for the supplier because the most lasting correction will involve a culture change from top to bottom.

One way to start the change would be to buy or create a Deming Red Bead kit and script and run everyone through the "experiment" from CEO down to the guy who sweeps the floors. Once folks "get it" that nonconformance originates in the process, then and only then is there a possibility of changing the process and culture.
 
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potdar

#13
Re: How to react? Inspecting Quality into Product

One way to start the change would be to buy or create a Deming Red Bead kit and script and run everyone through the "experiment" from CEO down to the guy who sweeps the floors. Once folks "get it" that nonconformance originates in the process, then and only then is there a possibility of changing the process and culture.
RC, Wes,

Dont I know that prevention is better than cure? That corrections are temporary measures? What I have suggested is only a way to make the folks Get it. In the situation discussed, in my opinion, this is the only bitter pill that will work, if at all.

In another thread we had all discussed about 'politics at workplace', yet another about 'QA folks being policemen' ..

I have advised Yeong to offer help to his boss once he is forced to come round. Thats when corrective action starts, and maybe preventive. Till then, it is plain not feasible.

I have also qualified by asking him to think seriously before he tries this solution. I have tried it successfully, but almost lost my job in the process. So, its a very thin line to tread, but the only feasible technique in my opinion that may yield results. The nice techniques in all the textbooks dont work in such situations.

What do you think will be the reaction of the Boss and the CEO and even the Janitor if our friend starts talking of Deming and red beads?
 

Wes Bucey

Quite Involved in Discussions
#14
Re: How to react? Inspecting Quality into Product

What do you think will be the reaction of the Boss and the CEO and even the Janitor if our friend starts talking of Deming and red beads?
If he says, "Hey! Look what these guys say some of the best companies are doing. Do we want to be one of the best companies? Why don't we at least check it out?" they just may check it out. If we just tell the guy to duck low and :ca: nothing will ever change and we may end up buying a defective product that slipped through inspection.
 

Sidney Vianna

Post Responsibly
Staff member
Admin
#15
Re: How to react? Inspecting Quality into Product

What do you think will be the reaction of the Boss and the CEO and even the Janitor if our friend starts talking of Deming and red beads?
Nobody knows what their reaction will be. Maybe they would listen to a proposal that involves LESS inspection, less defects and less customer returns. The obvious answer is that tightening inspection is not addressing the root cause of the problem.

potdar said:
As you say, it is a warlike situation for you.
No. This is not like a war. Not even close.
potdar said:
Everything is fair in war.
ABSOLUTELY NOT. :mad:
 
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potdar

#16
Re: How to react? Inspecting Quality into Product

Well, lets not fight over it. Let Yeong read through all opinions, try whatever he thinks fit in whatever sequence he deems fit. It will be his decision and his responsibility for the consequences.

All of us, including him, know that inspection is not the solution.

It is the real problem that we are disagreeing on. You say that the real problem is that bad parts are being made. I say that the real problem is that the people who matter dont agree that it is a problem.
 

Wes Bucey

Quite Involved in Discussions
#17
Re: How to react? Inspecting Quality into Product

It is the real problem that we are disagreeing on. You say that the real problem is that bad parts are being made. I say that the real problem is that the people who matter dont agree that it is a problem.
It isn't they don't agree it is a problem; they don't even suspect it is a problem to agree or disagree!
 
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potdar

#20
Re: How to react? Inspecting Quality into Product

In SUCH a case, the only option....

In WHAT case? I think you are taking pieces of my posts out of context and putting them together to make my wife catch me!

I think lets wait for Yeong to come back to the thread and comment on the on site situation. If it is mrkedly different than what I suspect it is, he will reject my suggestions outright. And so he should.

When a bitter pill is not called for, it should not be put to use. It only leves bitter taste all round.
 
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