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Empowering Manufacturing Excellence: How We Built a Tool Replacement Management System That Saves Time, Reduces Risk, and Secures Customer Funding
1. Introduction In high-volume automotive manufacturing, tooling health across injection molds, stamping dies, and casting dies—is mission-critical. Unexpected tool failures can cause production delays, quality issues, and costly customer escalations. To address these risks, I led a cross functional team to launch a Tool Replacement Management Project to move from reactive firefighting to a proactive,…
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Cost of Poor Quality Metric for Individual Suppliers and Business decisions on risk based approach
Traditionally, quality costs have particularly emphasized the cost of non-conformances. Important as this cost, we also need to estimate the cost of inefficient processes. This includes cost of redundant operations, sorting inspections, and other forms of non-value added activities. The American Society for Quality (ASQ) categorizes cost of poor quality into 4 segments. Internal Failure…
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Monitoring Cost of Quality and Merging with Non Conformance Reports
The purpose of cost of quality (COQ) technique is to provide a tool to management for facilitating quality program and quality improvement activities. Quality cost reports can be used to point out the strengths and weaknesses of a quality system. Quality costs can define the activities of quality program and quality improvement efforts in a…
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Supplier Performance monitoring with Business Analytics
I’m sure we all at some point wondered about the biggest quality issue our company has. If you are working in a multinational company with production operations in more than 2-3 countries, streamlining multiple sources of data and arriving to a meaningful conclusion to some of the deep rooted process issues is a challenging task.…
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An overview of 8D and why “Operator Error” or “Training” are not corrective actions for problem rootcause.
The 8 Disciples (8D) of Problem Solving Process is one of the most effective problem solving processes that can be successfully applied in many different types of industries and organizations to identify and eliminate the underlying symptoms/root causes of a problem. Serious consequences occur when an elaborate problem solving procedure like 8D is not implemented…
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Why is Quality Assurance equally if not more important than Quality Control?
My experience has taught me that most of the manufacturing quality problems can be addressed with proper implementation of quality standards. It is very important for all quality personnel including technicians, inspectors to understand these standards and comply accordingly. Lack of proper procedures in place and urge to comply to standards for the sake of…
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The Journey Begins
Thanks for joining me! Good company in a journey makes the way seem shorter. — Izaak Walton
Quality Thinking 