How to reduce Cost of poor quality

Purpose Quality cost is an important parameter in any industry, it is imperative to have quality cost as an metric in the management review meetings Current scenario Quality cost is due to following reasons External failures customer complaints ,warranty failures Internal failures inprocess rejections,rework,scrap

We are going to discuss mainly on how to reduce the cost of poor quality Internal failures Internal failures happens mainly due to following reasons

Due to improper assembly problems Due to child parts dimensional deviatinos Due to Tolerance stackup problems Design problems Due to design which cannot be manufactured Manufacturability of the product

Due to improper assembly problems The assembly machine is not manufactured to the requirement-The assembly reference points are not taken as per drawing, fixtures not made according to the part tolerance. Poka yoke not planned in advance, calibration not done in testing machines Check points required to monitor the conditions of the assembly machines .Preventive maintenance to be planned ,also take care of manufacturer suggested maintenance procedures. Child parts dimensional issues Inprocess rejections in an assembled product will be mainly contributed by the poor quality of the child parts. The main root causes are Poor process/Machine capability Poor process selection

Poor machine selection Improper jigs and fixtures Improper process parameters

As an important activity feasibility study should be done thoroughly along with the supplier .Each and every aspect of the product should be analyzed. Supplier capability problems Supplier is not having capability to produce good parts with process capability. Supplier selection should be so shrewd that all the points like Man, machine, technology, Metrology, methods, systems, supplier experience in producing the similar parts, suppliers interest in the business. Supplier selection should have a stringent procedure so that all the crucial criterias are taken care by the procedure. Once supplier is selected and before awarding the business all the requirements of the products ,criterias and quality system required by our organization should be clearly defined and agreed upon the supplier. Once the business is awarded a clear project plan should be prepared along with supplier with clear cut target and goals and proper gates to review the progress. When a specific process like die casting ,stamping tools and machining fixtures are developed we have to ensure that all the relevant international standard are followed since the cost of developing the tools are very high and any rework will cost you more. Ensure all the standards related to product and functional requirements are shared and understood. All the process inspection requirements should be clearly defined by the supplier. During PPAP approval ensure that all the product criterias are met through proper layout inspection, material testing and all the process requirements like tool drawings, tool maintenance, tool life monitoring, operator training, work instructions, Measurement methodology for incoming, in process and final inspection at supplier end ,quality alerts, incoming inspection standards, inspection agreement are properly done. Proper setup approval inspection to be established at supplier end . Mainly all the critical dimensions should be identified and process capability should be proved during PPAP approval. A clear cut statistical process control procedure should be established to control the critical dimensions. Once the regular production started with suppliers, Preventive and corrective actions procedure shall be agreed with supplier. A supplier quality manual with all the above included should be prepared and agreed with suppliers. To eliminate the above said root cause proper problem solving technique should be used according to the process and improvement project shall kick off Stack up problems Design problems

The stack up or design problem will be revealed during the proto type assemblies ,design validation testing, and prototype parts assembly at customer end. All the problems shall be recorded and analyzed properly to resolve all the design problems. CATIA,Autocad and all other techniques should be used to identify all design related issues

Manufacturability of the product During the design and development process manufacturability of the product should be thoroughly analyzed. Each and every part of the assembly should be thoroughly discussed with supplier for the manufacturability of the product.