80% Of Motor Quality Problems Are Management Problems!

80% of motor quality problems are management problems!

 

Misunderstanding of quality issues

 

Product quality is produced, not tested. Only in each link of the production process, in strict accordance with the requirements of the production process and operation instructions, can the quality of the product be guaranteed. If you ignore the process control, only rely on inspection, it is impossible to ensure product quality, because quality inspection, can only eliminate defective products and waste products, can not improve product quality.

 

In other words, the focus of quality control must not be on the after-the-fact, but must be placed on the manufacturing stage, that is, the production process stage.

However, many companies, once there is a quality problem, 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:

 

1) Allow a small number of defects, accidental defects are inevitable;

2) Quality is the responsibility of the quality control department;

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

4) If there is a problem, I think it is a matter of the quality department.

 

I think many friends who do quality work have more or less felt this way. Often when writing a report, the quality department completes it alone, and the other departments basically do nothing; The boss feels that quality is not very important, research and development is very important, and making money is the most important. Therefore, the quality department does not have any status in the company, and often says a few words of truth and is flashed.

 

Why do quality issues occur?

 

Causes of quality problems:

 

 

1) If the problem is not handled well before product development, and the mass production pass-through rate is too low, it is hoped to rely on quality to fight the fire, and want to reduce defective or unqualified products by increasing the frequency of testing;

 

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

 

3) The customer urges the goods, the pressure is applied above, the boss speaks according to his so-called actual experience, and implements special release for products that are not within the standard range, resulting in product problems;

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

 

Non-artificial quality problems occur in the production process, but they are not within the detection frequency range.

 

A real case of quality

 

Case 1: An auto part, using ABS (750SQ) produced by a company, used 3.4 tons, and found that the plastic parts made of this raw material had black spots on the surface, resulting in unqualified products and huge losses.

 

 

Case 2: A company produces white film for milk film, all the testing items are qualified, so the method leaves the factory, but when the film manufacturer uses it, it finds that the masterbatch smells more unpleasant, and later complains. Finally, the order of several hundred tons, because of such a quality problem, yellow. Fortunately, the user did not produce the film, otherwise it would be really unimaginable.

 

Case 3: The engineering masterbatch produced by a company has a color difference due to the lack of strict color control, resulting 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 product manufacturers in the process of using plastics, plastic bubbles appear, resulting in a large number of unqualified products, the last tens of tons of plastic, all returned, and compensation for the losses that have been caused.

 

It is not uncommon for plastics to appear in quality. If these situations have to be blamed by the quality department, it is really unjust.

 

The author believes that every link of the quality management system requires quality control, and these controls are obviously not fully undertaken by the quality inspection department or quality management department, and these controls must be implemented by personnel in the best position. For example, some products in the production process to find quality problems are easy, but in the inspection is difficult to find, at this time, the production operator is obviously better than the quality inspector to understand the quality problem, if the operator does not take the initiative to control the quality, only rely on the quality inspector to check, 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 all guaranteed by procurement, processing and manufacturing, packaging, and transportation. Therefore, product quality is achieved in the design and production process, and quality is achieved through process management.

 

How to control product quality:

 

1. Establish the awareness that quality is the lifeblood of the enterprise

 

It is necessary to realize that the quality of the product is not good, the product has no market, the product has no market, the enterprise will lose the source of profit, and after a long time, the enterprise will go bankrupt, followed by employee unemployment. Of course, for the company, even if the product market is good, it is necessary to "think of danger in peace", make the product quality better, and create a better corporate reputation. As the saying goes, "If you bloom, the breeze will come."

 

2. Establish customer awareness of quality

 

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

 

3. Establish a quality awareness of prevention

 

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

 

4. Establish a procedural awareness of quality

 

Quality management is the whole process, the whole company, and between each process, the work between the departments of the whole company must be orderly and effective, requiring all quality management personnel and operators to strictly follow the procedure, if not according to the procedure The opportunity to work will increase, and the quality of the product cannot be guaranteed.

 

5. 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 defects about 80%, operators controllable defects are generally less than 20%. While improving the management level, the operator must also understand the following four points:

 

1) the operator knows how and why he does it;

2) The operator knows whether the products he produces meet the requirements of the specification;

3) the operator knows what will happen if the product he produces does not meet the specifications;

4) The operator has the ability to correctly handle abnormal situations.

 

6. Establish a sense of continuous quality delivery

 

Quality is not the best, 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, develop an improvement plan;

D- Implementation: implementation plan;

C-Inspection: according to product requirements, the process and product are inspected;

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

 

7. Establish the cost awareness of quality

 

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

 

8. Establish a sense of quality education

 

With the development of the times, the concept of quality management is constantly updated and needs to be learned. Successful enterprises in the new era will belong to those learning and growth enterprises, strengthen internal training, improve the ability of all employees to work and innovate, will make the enterprise prosperous and change with each passing day. Therefore, "quality begins with education and ends with education."

 

Facts have proved that those successful enterprises are strictly in accordance with the concept of "products are produced" to strictly carry out product production, they strictly control every link of product production, 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, in order to withstand the test of the market.