80% of factory quality problems are caused by management!

Product quality is produced, not inspected - before Dr. William Deming, the American quality management master, put forward the concept of "product quality is produced, not tested", the early quality management was limited to quality inspection, and only the quality of the product could be checked after the fact.

William Deming's quality quote pointed out that the quality of the product can only be guaranteed in strict accordance with the requirements of the production process and work instructions in every link of the production process. If you ignore the process control and rely only on inspection, it is impossible to ensure product quality, because quality inspection can only eliminate defective products and waste products, and cannot improve product quality. In other words, the focus of quality control must not be placed on the post-fact, but must be placed in the manufacturing stage, that is, the production process stage.

However, many companies, once they have quality problems, push the responsibility to the quality department, thinking that this is the responsibility of the quality department, because many companies have such a wrong view:

A few undesirable and unexpected defects are unavoidable;

Quality is the responsibility of the quality control department;

Only pay attention to the inspection of products, and inspectors need to be responsible for solving defective products;

If something goes wrong, I think it's the quality department's business.

I think many friends who do quality work have felt this way to a greater or lesser extent. Often when writing a report, the quality department completes it alone, and other departments basically don't care; The boss thinks that quality is not very important, research and development is very important, and making money is the most important thing. Therefore, the quality department does not have any status in the company, and often says a few words of truth, and it is time to flash people.

Why do quality problems occur?

If the problem is not dealt with well before product development, and the first-pass rate of mass production is too low, it is hoped that the quality will be used to fight the fire, and the frequency of testing will be increased to reduce defective or unqualified products;

Add reworked materials, unqualified materials, but have not been tested and verified in advance, and there is no accurate recognition of product quality fluctuations;

The customer urges the goods, and the boss puts pressure on him, and the boss speaks according to his so-called actual experience, and implements special release for products that are not within the scope of the standard, resulting in product problems;

The industry has improved the quality standards of products, and the company still produces according to the original standards;

There are non-human quality problems in the production process, but they are not within the detection frequency range, etc.

A real-life example of quality

Case 1:

After using 3.4 tons of ABS (750SQ) produced by a company, it was found that there were black spots on the surface of the plastic parts made of this raw material, resulting in unqualified products and huge losses.

Case 2:

A company produces white film for milk film, and all the testing items are qualified, so the method leaves the factory, but when the film manufacturer uses it, he finds that the masterbatch tastes more unpleasant, and later complains. In the end, hundreds of tons of orders were yellow because of such a quality problem. Fortunately, the user did not produce the film, otherwise the consequences would be really unimaginable.

Case 3:

The engineering masterbatch produced by a company is not strict in color control, resulting in color difference in the use of plastic parts produced by the company, resulting in customers no longer using the company's plastic products.

Case 4:

Due to the lack of strict control of plastic moisture, plastic products manufacturers in the process of using plastics, plastic bubbles appear, resulting in a large number of substandard products, and the last dozens of tons of plastics, all returned, and compensation has been caused.

Cases of quality of plastics are not uncommon. If the quality department has to carry the black pot in these situations, it is really too wrong.

The author believes that every link of the quality management system needs to carry out quality control, and these controls are obviously not fully undertaken by the quality inspection department or the quality management department, and these controls must be implemented by the personnel in the best position. For example, it is easy to find quality problems in the production process of some products, but it is difficult to find them in the inspection, at this time, the production operator obviously knows more about the quality problem than the quality inspector, if the operator does not take the initiative to control the quality, only rely on the quality inspector to check, the product quality is difficult to be fundamentally guaranteed.

How to control product quality in an all-round way

The product is basically positioned in the design stage, and then the quality is guaranteed by procurement, processing and manufacturing, packaging and transportation. So product quality is achieved in the design and production process, and quality is achieved through process management. How to control product quality:

First, establish the awareness that quality is the lifeblood of the enterprise

All employees should realize that if the quality of the product is not good, there will be no market for the product, and if there is no market for the product, the enterprise will lose its source of profits, and after a long time, the enterprise will go bankrupt, followed by the unemployment of employees. Of course, for the company, even if the product market is good, it is necessary to "be prepared for danger in times of peace", make product quality better, and create a better corporate reputation. As the saying goes, "If you bloom, the breeze will come."

Second, establish a sense of quality customer awareness

Everything is customer-centric, see yourself as a customer, see yourself as the operator of the next process, and see yourself as a consumer of the product. In this way, in the work will consciously do a good job, everyone will do a good job, the quality of the product will be guaranteed, if you cut corners in the work, the harm will be your own vital interests.

Third, establish a sense of quality prevention

"The quality of the product is produced and designed, not by inspection, and things must be done well in the first time." This is not a slogan, which is a good reflection of the preventive nature of product quality, if the quality control does not start from the source, it will be difficult to control the quality of the product.

Even if a large amount of inspection manpower is invested in the production to check, the cost of the product will be greatly increased due to a large number of defective products or even waste products that are not controlled from the source during production. Moreover, the quality problems of some products may not be found and made up for from the subsequent process, which requires us to do things well in the first time to prevent the occurrence of quality problems.

Fourth, establish a sense of quality procedures

Quality management is the whole process, the whole company, and between the various processes, the work between the departments of the company must be orderly and effective, requiring all quality management personnel and operators to do it in strict accordance with the procedure, if not according to the procedure the opportunity to make mistakes will increase, and the quality of the product can not be guaranteed.

Fifth, establish a sense of responsibility for quality

80% of quality problems come from management, and only 20% of problems originate from employees, that is, managers can control about 80% of defects, and operators can control defects are generally less than 20%. While the manager improves the management level, it is also necessary to make the operator understand the following four points:

The operator knows how and why he does it;

The operator knows whether the product he produces meets the requirements of the specification;

The operator knows what the consequences will be if the product he produces does not meet the specifications;

The operator has the ability to correctly handle abnormal situations.

If the above four points have been met and the material conditions such as equipment, tooling, testing and materials in production are met and the failure still occurs, it is considered to be a defect controllable by the operator; If any of the above four points cannot be met or the material conditions such as equipment, tooling, testing and materials in production are not available and cause failure, it is the responsibility of the management personnel. Only by understanding the responsibility of quality problems can we improve the problems and improve the quality in a targeted manner.

Sixth, establish a sense of continuous delivery of quality

There is no best quality, only better; Quality improvement is a continuous and continuous improvement process, which follows the PDCA model, which can be briefly described as follows:

P—Plan: According to the requirements of the product, formulate an improvement plan;

D – Implementation: Implementation plan;

C—Inspection: According to the product requirements, the process and products are inspected;

A—Disposal: Take measures to continuously improve product quality.

Only in this way will the quality of our products continue to rise, and only in this way will we continue to improve quality and innovation, and we will continue to win in the market.

Seventh, establish a cost consciousness of quality (i.e., quality standard awareness)

Ensuring quality and pursuing profits is the eternal goal of the enterprise. To develop, enterprises have to pay attention to the cost of production, but the cost is closely related to quality, good quality, can reduce the cost of the product to a minimum, if the quality of the product is not good, often by customer return complaints, then his cost will remain high, and even force the enterprise into a desperate situation.

The reason for the decline of many enterprises: not because there are no customers and no orders, but because the internal management of the enterprise is not good, the cost can not be reduced and cannot participate in market competition, and enterprises should take warning.

But the stricter the quality, the more beneficial it is to the enterprise. On the contrary, excessively improving product quality will lead to overquality, which will also increase production costs. Therefore, when we are in production, we require all processes and links to be done in strict accordance with customer standards, so that we can minimize costs and improve market competitive advantage.

Eighth, establish a sense of quality education

With the development of the times, the concept of quality management is constantly updated, and it needs to be learned. Successful enterprises in the 21st century will belong to those learning and growing enterprises, strengthen internal training, improve the ability of all employees to work and innovate, will make the enterprise thriving and changing with each passing day. Therefore, "quality begins with education and ends with education." ”

Facts have proved that those successful enterprises are in accordance with the concept of "products are produced" to strictly produce products, they strictly control every link of product production, to ensure that the quality of each link does not go wrong, one link is closely linked, so that the products produced are qualified and good products, and can stand the test of the market.

Details determine success or failure, attitude determines everything, only to establish a strong sense of quality, excellence in quality, tireless and persistent pursuit, in order to do a good job in the quality of Tongdeli, in order to improve the quality to a new height, Tongdeli this giant ship in the stormy waves to ride the wind and waves, bravely move forward, in order to go higher and further.