Poor Manufacturing Planning fixes

E

Eloy Gomez

#1
Hello: Not sure if I am posting in the right section.

We track weekly all our internal manufacturing planning errors, such as planning with wrong revision, wrong information, missing information, needs update, etc....

Well for the month of January there were 90 manufacturing plans corrected at a high internal cost. Labor cost and materials.

40% of bad planning was due to planning having the incorrect revision - another 40% was due to wrong manufacturing information on the plan - Remainder 20% is form missing information.

If we tackle just the incorrect revision problem we could it would be a big chunk of noncoformance removed (40%). I am having a meeting with the Planning department next week and would like to know if I could be helped with some ideas or quality tools I can use to start implementing change.

Yes, I know all they need to do is review the planning before is released but being in a high paced area most of what they do is copy and paste therefore releasing poor planning. Thanks in advance for your suggestions.
 
Elsmar Forum Sponsor

Stijloor

Staff member
Super Moderator
#2
Hello: Not sure if I am posting in the right section.

We track weekly all our internal manufacturing planning errors, such as planning with wrong revision, wrong information, missing information, needs update, etc....

Well for the month of January there were 90 manufacturing plans corrected at a high internal cost. Labor cost and materials.

40% of bad planning was due to planning having the incorrect revision - another 40% was due to wrong manufacturing information on the plan - Remainder 20% is form missing information.

If we tackle just the incorrect revision problem we could it would be a big chunk of nonconformance removed (40%). I am having a meeting with the Planning department next week and would like to know if I could be helped with some ideas or quality tools I can use to start implementing change.

Yes, I know all they need to do is review the planning before is released but being in a high paced area most of what they do is copy and paste therefore releasing poor planning. Thanks in advance for your suggestions.
In the automotive industry, a planning tool called Advanced Product Quality Planning (APQP) is used. This process includes a series of recommended planning steps that (if implemented correctly) will reduce errors and problems later on. Conduct a search on APQP and see what pops up.

For example, a search in "Post Attachments" yielded these results.

Here is an APQP presentation developed by our host Mr. Marc Smith.

Stijloor.
 
Last edited:
H

Hodgepodge

#3
Hello: Not sure if I am posting in the right section.

We track weekly all our internal manufacturing planning errors, such as planning with wrong revision, wrong information, missing information, needs update, etc....

Well for the month of January there were 90 manufacturing plans corrected at a high internal cost. Labor cost and materials.

40% of bad planning was due to planning having the incorrect revision - another 40% was due to wrong manufacturing information on the plan - Remainder 20% is form missing information.

If we tackle just the incorrect revision problem we could it would be a big chunk of noncoformance removed (40%). I am having a meeting with the Planning department next week and would like to know if I could be helped with some ideas or quality tools I can use to start implementing change.

Yes, I know all they need to do is review the planning before is released but being in a high paced area most of what they do is copy and paste therefore releasing poor planning. Thanks in advance for your suggestions.
This sounds like a management issue. When answers like “not enough time”, “high paced area”, and “if I took the time to check every one, it would take forever”, are accepted for why quality is poor, it is because management has accepted those answers. The culture of quality is created by management’s attitudes and their coinciding actions. It is management’s job to provide the resources to ensure quality, whether it is a process, training, manpower, or motivation.

If management feels the process, when done properly, is efficient and effective and believes the training program for the employees performing the task is adequate, then the employees are simply being allowed to produce poor output. Once management stops accepting the poor output, by assigning appropriate consequences which may include disciplinary actions or termination, the poor output will be reduced.

“High paced area” & “I don’t have enough time” are not acceptable excuses. First, make a good product, then work on producing it faster. Is the process, if done properly, efficient and effective? If not, then management is failing. If the process owners are being pushed to just get it done regardless of the quality, then management is failing. Perhaps a new or improved process is necessary, however, you can have all the APQP guidelines in the world, if management isn’t committed to quality, they won’t be successfully implemented.
 

Golfman25

Trusted Information Resource
#4
Sounds to me that you don't have any standardization. Most of the information should be computer controled (ie; latest rev level), not cut and pasted. Once entered properly into the system, it should flow thru. Good luck.
 
D

DrM2u

#5
I agree with Hodgpodge's comments! It seems like what you need is a change in culture but a thorough root cause analysis might uncover more than that. Updating documents and specs will be a never-ending battle and the problems will constantly stick out their ugly heads until the root cause is addressed. I would strongly suggest that you focus your efforts on a in-depth root cause analysis instead of tackling 'the incorrect revision problem '. Like Napoleon said, "incidents should not govern policy; but, policy incidents".
 
Thread starter Similar threads Forum Replies Date
S Cost of Poor Quality (CoPQ) - Scrap element of calculation includes lost margin? Misc. Quality Assurance and Business Systems Related Topics 7
qualprod Addressing poor commitment in people Misc. Quality Assurance and Business Systems Related Topics 23
qualprod Best criteria to measure Corrective Action effectiveness - Poor Maintenance ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
C What is your Cost of Poor Quality (COPQ)? Misc. Quality Assurance and Business Systems Related Topics 8
V For screening a design, can we live with the low/poor predicted R-Sq.? Statistical Analysis Tools, Techniques and SPC 3
M Reducing Cost of Poor Quality - Your opinion requested Quality Manager and Management Related Issues 14
M Contractors with poor Quality Records ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 9
M Customer Satisfaction Survey - Poor Response ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 11
S Difference between COQ (Cost of Quality) vs COPQ (Cost of Poor Quality)? Misc. Quality Assurance and Business Systems Related Topics 8
X Poor GR&R results due to Low Part Variation Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 20
M Which metric is better for Cost of Poor Quality (COPQ)? Quality Tools, Improvement and Analysis 17
N Improving Poor Communication with Customers Customer Complaints 6
Y Poor Gage R&R Results - High R&R result and poor ndc value Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
P Smart or Sexy (CAR) - Poor Root Cause Analysis and Poor Effectiveness Check Nonconformance and Corrective Action 8
Y FDA News bulletin: It's the FDA's fault! FDA at Fault for Poor Quality Devices US Food and Drug Administration (FDA) 6
F Poor Containment - Supplier Nonconformance Problem Solving, Root Cause Fault and Failure Analysis 7
R Development Rejection Costs in COPQ (Cost of Poor Quality) Calculations Misc. Quality Assurance and Business Systems Related Topics 6
AnaMariaVR2 Poor Writing Skills Overshadow Good Content, Credibility & Revenues Records and Data - Quality, Legal and Other Evidence 19
1 Cost of Poor Quality form or template wanted Quality Tools, Improvement and Analysis 1
S COPQ (Cost of Poor Quality) Vs PONC (Price of Non Conformance) - Explanation wanted Quality Manager and Management Related Issues 5
P Measuring Costs of Poor Quality Quality Manager and Management Related Issues 2
A Chaotic Industry, Poor Service From Almost Everyone Coffee Break and Water Cooler Discussions 12
M Cost of Poor Quality Reports IATF 16949 - Automotive Quality Systems Standard 15
K Generic worksheet for calculating Supplier Chargeback and Cost of Poor Quality (COPQ) Supplier Quality Assurance and other Supplier Issues 2
N Personnel COPQ (Cost of Poor Quality) Quality Manager and Management Related Issues 6
P Evidence of Supplier Corrective Action - Poor Responses by Suppliers ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
Marc Poor Hungry Kitty Funny Stuff - Jokes and Humour 8
S COPQ (Cost of Poor Quality) - Can we add Premium Freight? Misc. Quality Assurance and Business Systems Related Topics 6
S COPQ - Cost of Poor Quality - COPQ course for non-financial people Misc. Quality Assurance and Business Systems Related Topics 1
N Identification of COPQ (Cost of Poor Quality) aspects Quality Tools, Improvement and Analysis 2
bobdoering Consumer Reports: Poor Man's Opera Coffee Break and Water Cooler Discussions 0
S Examples of major problems caused by Poor document control Document Control Systems, Procedures, Forms and Templates 14
T Poor Capability - Electric torque screwdriver Capability, Accuracy and Stability - Processes, Machines, etc. 2
H Cost of Poor Quality (COPQ) - All returned/defective parts (plastic) are recycled Training - Internal, External, Online and Distance Learning 7
Manix Cost of Poor Quality (COPQ) and Reputation Quality Tools, Improvement and Analysis 25
Z Consequences for Poor Performance based on a Monthly Scorecard - Actions? Supplier Quality Assurance and other Supplier Issues 15
I High COPQ (Cost Of Poor Quality) from Our Quality Department IATF 16949 - Automotive Quality Systems Standard 7
N Poor control of testing chemicals ? which ISO 13485/9001 clause does it contravene? ISO 13485:2016 - Medical Device Quality Management Systems 8
S New Auditor wants Mould tool repair bill included in Cost of Poor Quality! IATF 16949 - Automotive Quality Systems Standard 18
M Poor Gage R&R results (30%RR to 80%RR) - What Next? Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 6
Z Creating and Maintaining a Top Ten Poor Quality Supplier Performer List Supplier Quality Assurance and other Supplier Issues 16
S Operator Capability - Gage R&R Poor Repeatability Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 8
M One weakness of audit non-conformance reports is the poor writing Miscellaneous Environmental Standards and EMS Related Discussions 10
S Is there any standard for "Cost of Poor Quality" (COPQ) by ISO Various Other Specifications, Standards, and related Requirements 5
J Cost of Poor Quality (COPQ) - Iceberg picture Quality Tools, Improvement and Analysis 4
D Scary stories - the REAL consequences of poor quality Misc. Quality Assurance and Business Systems Related Topics 3
B Machine failure defects due to no/poor maintenance for FMEA - Looking for examples FMEA and Control Plans 6
M Need input - Potential poor external auditor? My first ISO 14001 registration audit ISO 14001:2015 Specific Discussions 4
P Acronym COPQ (Cost of Poor Quality) and COQ (Cost of Quality) - Differences Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 26
L TS 16949 Clause 5.6.1.1 - Cost of "POOR" Quality vs. Cost of Quality IATF 16949 - Automotive Quality Systems Standard 4

Similar threads

Top Bottom