Reducing Cost of Poor Quality - Your opinion requested

[Milton Benn]

Hello All,
I would greatly appreciate any and all feedback to the question below.
In your opinion, what is the one most valuable task, strategy or methodology that a quality assurance team can apply and drive in their organization to support their organization in achieving consistent reduction in cost of poor quality over time?
There are many possible answers to the above question and just as likely many differing opinions on the one, best answer. And that?s what makes a discussion like this interesting. So if you have one, please share your opinion on the single most important thing that you believe the quality assurance team can do to help the organization drive down cost of poor quality?
Just to be fair, I?ll throw out my opinion on the topic. If I had to choose one specific task to drive in my organization to help the organization to consistently reduce the cost of poor quality it would be this?
Teach the organization (all functions / departments / people) about prevention. Not just once, not just twice, but on an ongoing basis until the concept of ?prevention? becomes part of our cultural environment. Prevention in design and development, prevention in supply chain, and prevention in execution of all products, services, and processes that define my organization and create the bottom line that keeps us all employed. If every employee in my company clearly and without a shadow of a doubt understood and engaged themselves in the application of a prevention or risk management approach in everything they do at our place of employment I would be a happy camper. If I had employees coming to me proactively on a regular basis asking me ?what else can I do to prevent mistakes? instead of asking me ?what can I do to fix this mistake? I would consider much of my job as a QA Mgr. complete. Yes, there is a question of tools and methods to achieve the outcome, but the first step has to be in my opinion to get everyone educated enough to recognize that consistent application of prevention / risk management is the starting point to a path of least resistance to a healthy bottom line. A cultural change to be sure.
So, there?s my two cents on the one most important thing that a quality assurance team in an organization can do to reduce CoPQ leading to a healthier bottom line. So how about your two cents? Care to share?
Best Regards,
Milton Benn

 

[jeremy01506]

Re: Your opinion requested - reducing cost of poor quality

I would say PFMEAs would give you your most bang for the buck when it comes to reducing cost of poor quality. By utilizing a cross-functional team and reviewing the potential risks associated with everything it helps you to logically fix any gaps and work in a preventive mode rather than reactive. This is also a good chance to put in as many Poka Yoke fixes as possible and (hopefully) further reduce the need for inspections, which will also reduce your cost of quality!

 

[normzone]

Re: Your opinion requested - reducing cost of poor quality

All that said and failing, an effective corrective action process with real root cause analysis. All the key players must be committed. Funnest meeting in the house...

 

[Sean Kelley]

Re: Your opinion requested - reducing cost of poor quality

I always break down COPQ into categories and identify the big hitters and put a team towrds driving down the big ones first. I usually find the top 3 reasons account for more than half of the COPQ and sometimes much more.

Driving these costs down take time typically 1-2 years before the results are apparent but with the comapanies I have worked for have seen many million $$ savings using this approach.

 

[John Broomfield]

"In your opinion, what is the one most valuable task, strategy or methodology that a quality assurance team can apply and drive in their organization to support their organization in achieving consistent reduction in cost of poor quality over time?"

Milton,

Development, use and improvement of your process-based organizational management system to determine and fulfill requirements

Thereby adding value faster and preventing loss sooner as you create more successful customers.

John

 

[Jen Kirley]

I have learned it's a mistake to look for the one most valuable thing because issues can be so diverse. These days I find human performance management to be among the most challenging - and PFMEAs won't help you with people problems.

 

[TWA - not the airline]

Thought about this a lot and for me what it boils down to is that the QA team should regard their role as a leadership function. QA should be a role model, educating, mentoring and making people aware of potential issues and consequences. They would thus prevent problems and help people to help themselves. And if something really goes wrong QA needs to lead the effort to set things right. My

 

[Chennaiite]

Hello All,
I would greatly appreciate any and all feedback to the question below.
In your opinion, what is the one most valuable task, strategy or methodology that a quality assurance team can apply and drive in their organization to support their organization in achieving consistent reduction in cost of poor quality over time?

An as-usual question. Is your Top Management on board with Carrot and Stick?

 

[TWA - not the airline]

An as-usual question. Is your Top Management on board with Carrot and Stick?

Chennaiite, you're probably right. It's a typical "holy grail" question and only Top management would be stupid enough to think that the quest for the holy grail is not about enlightenment but simply to find the one-and-only tool to solve all problems w/o the need to think

 

[JLyt207]

I have learned it's a mistake to look for the one most valuable thing because issues can be so diverse. These days I find human performance management to be among the most challenging - and PFMEAs won't help you with people problems.

I agree it is a mistake to look for one thing. If you have a hammer everything starts looking like a nail. I think it is important to be able to bring an entire toolbox to the table (to continue with the metaphor).

That said, I do think it is valuable to really take to heart the PDCA cycle in its broadest sense. It just improves whatever tool you use. The PFEMA you create today should be better than the PFEMA you did last year.