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Four major culprits of poor quality

The four main culprits of poor quality come from the four main aspects of the product making process, viz:

Wrong and bad design, leading to the product's inherent defects.

Too complex design, resulting in high cost and low quality.

Frequent design changes, resulting in a chaotic and error-prone process.

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Lack of process flow, BOM.

Lack of, wrong or inappropriate work standards.

No correct and reliable work fixture.

Lack of complete and correct inspection standards.

Inability to properly understand and implement work standards.

Inadequate process control capability.

Inadequate process quality audits and inspections.

Lack of quality consciousness and quality responsibility.

4

Poor quality of incoming materials.

Production plan is too rough, changeable, loose and tight.

Inadequate management and leadership.

Poor warehouse management.

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From the process point of view, the reasons for poor quality can be summarized from four aspects:

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Reason :

New employees : New employees are unfamiliar with the workflow and lack the necessary operational skills and knowledge.

Incompetence : Employees lack the specialized skills or work ethic required to perform their jobs.

Poor coaching: Inadequate training or guidance, or improper methods, resulting in employees failing to properly master work methods.

Countermeasures.

Setting work standards: Ensure that all employees have clear work instructions and work processes.

Appropriate assignments: Assign work appropriately according to employees' abilities and skills.

Proper employee training: Implement systematic training programs to ensure that employees fully understand work requirements and procedures.

2

Reason : Lack of tools : Employees do not have proper tools.

Lack of tools: Employees do not have the proper tools or equipment to do their jobs.

Wrong tools: Employees use incorrect tools or equipment, resulting in work errors.

Misunderstanding of standards: Inaccurate or inadequate understanding of work standards.

Lack of fail-safe design : Work processes or equipment are not designed to prevent errors from occurring.

Negligence : Errors are caused by inattention or carelessness.

Countermeasures.

Institutionalization of processes : Ensure that work processes are standardized to reduce uncertainty.

Work standardization : Establish and implement uniform work standards.

Simplify work: Simplify workflow to reduce complexity.

Foolproof tools: Use intelligent tools or equipment to reduce human error.

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Causes

Incoming material defects: Use of substandard raw materials or components.

Problems in the previous process: Problems in the previous process affect the current process.

Equipment Accuracy Problems: Equipment does not meet the required accuracy.

Incorrect instructions: Employees receive incorrect instructions or directions.

Incorrect standard: The work standard itself is incorrect or inadequate.

Inappropriate method: The method used is not suitable for the current job or environment.

Countermeasures.

Prevention of defective entry : Inspection and control of raw materials and components.

Equipment Maintenance and Early Warning : Regular maintenance of equipment and establishment of an early warning system to prevent equipment problems.

Three No's Principle ： Do not accept, do not manufacture, and do not pass on defective products, and strengthen quality awareness.

Correct principles for on-site problems : Ensure that employees understand the correct methods and principles for dealing with on-site problems.

4

Causes :

Management problem : Management does not pay enough attention to quality management or the management method is inappropriate.

Organizational problems: Inadequate organizational structure or processes that affect employees' motivation and efficiency.

Lack of pressure: Employees do not have enough pressure or motivation to work.

Lack of motivation: Employees lack incentives to improve quality.

Countermeasures.

Quality Competition: Stimulate employees' quality awareness through competition.

Implement QCC: Encourage employees to participate in quality control circle activities to enhance their sense of participation and responsibility.

Train the basic cadres : Train the basic managers to improve their management ability and quality awareness.

Regular review and revision of the system: Ensure that the company's system is incentive-based and can motivate employees.

Establishment of proper responsibility: Define the duties and responsibilities of employees to ensure the effectiveness of quality management.