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D
David DeLong
I always remember that when I began as a Quality Manager many, many years ago, we had Inspectors that checked product quality. The game at that time was that if an Inspector found "defective" product, the Inspector sorted it. That would certainly teach them not to find defective product in the future.
Believe me, that practice did not continue.
Today, companies should not really have Inspectors checking product quality but Quality Techs that would continuously confirm that the systems are being complied and, maybe, some testing. The production Operator checks for product quality and if there are non-conforming product that are deemed "defective", it would be the responsibility of manufacturing to organize and complete the sorting with all sorting costs charged against the department that produced the defective product.
Believe me, that practice did not continue.
Today, companies should not really have Inspectors checking product quality but Quality Techs that would continuously confirm that the systems are being complied and, maybe, some testing. The production Operator checks for product quality and if there are non-conforming product that are deemed "defective", it would be the responsibility of manufacturing to organize and complete the sorting with all sorting costs charged against the department that produced the defective product.
J
John Nabors - 2009
I wholeheartedly agree!
S
somerqc
Bekki,
I have and am feeling your pain. Over the last 10 years, I have only experienced 1 company that fully embraced accountability of the production staff for quality.
In that position, I was the "guy at the controls" so to speak. I monitored data and walked the floor (400,000 sq.ft facility - was in really good shape back then) to monitor processes and look for improvement opportunities.
The next closest was where everyone did take accountability for it (re: they took pride in their work) BUT we did have 5 line inspectors that reported to me and worked as "goalies". I strongly worked to eliminate this but that never happened in my tenure (ironically, they moved all production to China since thye were unable to compete......hmmm....). The company as a whole was run very well but had some legacy policies that resulted in money losses.
My current place is very similiar to your situation. All I can tell you is determine whether you think you can sell management on this...if not, move on. On Friday, I was talking to one of the owners (family owned) that was under the impression that I was responsible for physically doing the inspections! Yes, I very quickly corrected her. Did I mention I am a department of 1?!
That is a decision you need to make based on your own situation.
John
I have and am feeling your pain. Over the last 10 years, I have only experienced 1 company that fully embraced accountability of the production staff for quality.
In that position, I was the "guy at the controls" so to speak. I monitored data and walked the floor (400,000 sq.ft facility - was in really good shape back then) to monitor processes and look for improvement opportunities.
The next closest was where everyone did take accountability for it (re: they took pride in their work) BUT we did have 5 line inspectors that reported to me and worked as "goalies". I strongly worked to eliminate this but that never happened in my tenure (ironically, they moved all production to China since thye were unable to compete......hmmm....). The company as a whole was run very well but had some legacy policies that resulted in money losses.
My current place is very similiar to your situation. All I can tell you is determine whether you think you can sell management on this...if not, move on. On Friday, I was talking to one of the owners (family owned) that was under the impression that I was responsible for physically doing the inspections! Yes, I very quickly corrected her. Did I mention I am a department of 1?!
That is a decision you need to make based on your own situation.
John
J
JJ H20
Bekki,
I currently work in a metal stamping and fabricating facility. We have exactly the same issue here. There several relevant factors. First, to answer your question, everyone is responsible for quality. Even our operators check parts. However, this plant only recently began hiring quality professionals for managers. I was the second engineer to become a QM. When I started, I began measuring PPM, scrap, internal rejects, and such. The result was a shock when the trend charts came up in Management Review. Since then, the transition has been very painful for the entire management team. That is what you may be faced with.
On the up side, though there is much internal resistance, we have succeeded in reducing internal rejects by over 80%. Our PPM has been reduced by a similar percentage.
I currently work in a metal stamping and fabricating facility. We have exactly the same issue here. There several relevant factors. First, to answer your question, everyone is responsible for quality. Even our operators check parts. However, this plant only recently began hiring quality professionals for managers. I was the second engineer to become a QM. When I started, I began measuring PPM, scrap, internal rejects, and such. The result was a shock when the trend charts came up in Management Review. Since then, the transition has been very painful for the entire management team. That is what you may be faced with.
On the up side, though there is much internal resistance, we have succeeded in reducing internal rejects by over 80%. Our PPM has been reduced by a similar percentage.
M
MIREGMGR
For us, any time 100% inspection is required because of a breakdown of manufacturing controls, it's a big deal managerially. We may have just about anybody involved in the inspection process, at least as an observer and troubleshooter, up to the department managers, the President and the company owner. We try not to have to do that very often.
The general production expectation is that production people are trained regarding what they're making, and monitor the processes they operate. Quality's task is verification. We count scrap/rejects from every process and that data is reviewed weekly if it remains low, or continuously until fixed if need be.
The general production expectation is that production people are trained regarding what they're making, and monitor the processes they operate. Quality's task is verification. We count scrap/rejects from every process and that data is reviewed weekly if it remains low, or continuously until fixed if need be.
Q
Quality-Geek
UPDATE!!!
Thank you everyone for your input!
Apparently my boss is just as frustrated with this as I am. He and the Production Manager met and agreed that the Inspectors should be part of the Production department. Now all we're waiting on is approval from upmost management. That may be difficult, but the big dogs are really busy lately and don't have time to mess with things like this...
I don't have a problem with a small group of inspectors that check a few runs to verify the effectiveness of a countermeasure. Actually, I'd rather keep that little piece of the pie. It helps prevent bias. But right now I have several people on the production lines checking parts as they are made. Since it has become part of the production process, production needs to accept the responsibility. Besides, I'm tired of the "Well, who cares if we screwed up. Why didn't YOUR people catch it?" mentality.
Bekki
Thank you everyone for your input!
Apparently my boss is just as frustrated with this as I am. He and the Production Manager met and agreed that the Inspectors should be part of the Production department. Now all we're waiting on is approval from upmost management. That may be difficult, but the big dogs are really busy lately and don't have time to mess with things like this...
I don't have a problem with a small group of inspectors that check a few runs to verify the effectiveness of a countermeasure. Actually, I'd rather keep that little piece of the pie. It helps prevent bias. But right now I have several people on the production lines checking parts as they are made. Since it has become part of the production process, production needs to accept the responsibility. Besides, I'm tired of the "Well, who cares if we screwed up. Why didn't YOUR people catch it?" mentality.
Bekki
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