CNC Machining and CNC Machine Tools, Industrial enterprise management

Production is active, inspection is passive, and inspection is not produced.

“The product quality is produced, not tested, only in every aspect of the production process, strictly in accordance with the requirements of the production process and operating instructions, in order to ensure the quality of the product.” Do you agree with this sentence? The topic “Quality is produced or tested” has always been the focus of debate in the business community: Producers say that quality is tested, and inferior products flow into the market; inspectors do not have a good relationship; inspectors say that quality is production. Out of it, if the producers do not make substandard products, there will be no inferior products on the market! Is this a resultless debate? bearing steel

Today, many companies, once they have quality problems, push their responsibilities to the quality department, thinking that this is the responsibility of the quality department, because many companies have such wrong views:

Allowing a few bad things, accidental flaws are unavoidable;
Quality is the responsibility of the quality control department;
Only pay attention to product inspection, inspection personnel need to be responsible for solving defective products;
If something goes wrong, it feels like a quality department.

I think many friends who do quality work have had more or less the same feeling. Often when writing a report, the quality department completes one person, and other departments basically do not care; the boss thinks that quality is not very important, research and development are very important, and earning money is the most important. Therefore, the quality department does not have any position in the company, and often said a few words, it should be flash. bearing steel

So, is the product quality produced or tested?

First of all, we must analyze the relationship between first and second, active and passive. As we all know, the product is produced first and the test is later. In other words, only when the gentleman produces the product can it be tested. If there is no product, there is no way to test it.

Obviously: production is active and inspection is passive. Before the concept of “product quality was produced, not tested”, early quality management was limited to quality inspection, and only the quality of products could be checked afterwards.

William Deming’s famous quality statement pointed out that only in each step of the production process, in strict accordance with the requirements of the production process and work instructions, can we ensure the quality of the product. If you ignore the process control, relying solely on inspection, it is impossible to ensure product quality, because the quality inspection can only remove defective and waste products, and can not improve product quality. In other words, the focus of quality control must not be placed on after-the-scenes checks, but must be placed in the manufacturing phase, that is, the production process. bearing steel

Why do you have quality problems?

Before the product development, the problem is not handled well, and the mass production pass rate is too low. We hope to rely on quality firefighting, and we want to improve the frequency of inspections to reduce defective products or unqualified products; adding rework materials and unqualified materials without passing through Test and verification, there is no accurate knowledge of product quality fluctuations; customers push for goods, pressure on the above, the boss said according to their own so-called practical experience, for products not in the standard range, the implementation of special release, leading to product issues; Improve the quality standards of the products, the company still produces according to the original standard; There are non-human quality problems in the production process, but not in the detection frequency range… bearing steel

The real case of quality

Case number one:

An auto part, using a company’s ABS (750SQ), after using 3.4 tons, found that the surface of the plastic parts made from the raw materials had black spots, which caused the products to fail and caused huge losses.

Case 2:

A company produced a white film for a milk film, and all the test items were qualified, so the method was shipped. However, when the film manufacturer used it, it found that the taste of the masterbatch was unpleasant and later made a complaint. As a result, hundreds of tons of orders were yellow because of this quality problem. Fortunately, the user did not produce the film and it was really unthinkable. bearing steel

Case 3:

The masterbatch produced by a company, due to the lack of strict control over the color, caused the use of plastic parts produced by the company to cause color differences, thus resulting in customers no longer using the company’s plastic products.

Case 4:

Due to the fact that plastic moisture control is not strict, plastics manufacturers use plastics in the process of using plastics, resulting in a variety of air bubbles, resulting in a large number of unqualified products. The last dozens of tons of plastic, all return, and compensation for the losses caused.

There are many examples of quality plastics. If these conditions have to be thrown back by the quality department, then it is really awkward. The author believes that every aspect of the quality management system requires quality control, and these controls are obviously not fully borne by the quality inspection department or the quality management department. These controls must be implemented by the best-positioned personnel. For example, some products find quality problems in the production process is easy, but it is difficult to find in the inspection, at this time, the production operator is obviously more knowledgeable than the quality inspector on quality issues, if the operator does not take the initiative to control Quality, relying solely on quality inspectors checks, product quality is difficult to guarantee fundamentally. bearing steel

How to control product quality in all directions

The product is basically positioned at the design stage. The quality of the product is then guaranteed by purchasing, processing, manufacturing, packaging, and transportation. The quality of these processes is controlled and quality is naturally controlled. Therefore, product quality is achieved during the design and production process, and quality is achieved through process management. How to control product quality:

First, establishing quality is the lifeblood awareness of the company

All employees must realize that: if the quality of the product is not good, there will be no market for the product and no market for the product. The company will lose its source of profit. If it takes a long time, the company will fail and the employee will become unemployed. Of course, for the company, even if the product market is good, it is also necessary to “think dangerously in times of peace”, to do a better job of product quality, and to create a better corporate reputation. As the saying goes: “If you bloom, the breeze will come.”

Second, establish a quality customer awareness

Everything is customer-centric, considers itself as a customer, considers itself as the operator of the next process, and sees itself as the consumer of the product. In this way, the work will be done consciously, everyone will do a good job, the quality of the product will be guaranteed, if you cut corners in your work, the harm will be their own interests. bearing steel

Third, establish a sense of quality prevention

“The quality of a product is produced and designed. It does not depend on testing. The first thing we must do is to do a good job.” This is not a slogan. This is a good example of product quality prevention, if quality control. Without starting from the source, it will be difficult to control the quality of the product.
Even if a large amount of inspection manpower is put into production to control the production, a large number of defective products or even waste products that are produced from the source at the time of production will greatly increase the cost of the product. Moreover, the quality problems of some products may not be discovered and remedied from subsequent processes. This requires us to do a good job at the first time and prevent the occurrence of quality problems.

Fourth, establish a procedural awareness of quality

Quality management is the whole process and company-wide. The work between departments and departments must be orderly and effective. All quality management personnel and operators are required to strictly follow the procedures. If not, follow the procedure. The chance of work mistakes will increase, and the quality of the product will not be guaranteed. bearing steel

Fifth, establish a sense of responsibility for quality

80% of quality problems are due to management, and only 20% of problems originate from employees. That is, managers have about 80% controllable defects and operators have controllable defects of less than 20%. While improving the managerial level, the manager must also understand the following four points:

A. The operator knows what he did and why he did it;
B. The operator knows whether the product he produces meets the requirements of the specification;
C. The operator knows what consequences the produced product will not meet the specifications;
D. The operator has the ability to correctly handle abnormal conditions.

If the above four points have been satisfied and the failure of the equipment, tooling, testing, and materials under production conditions is still in place, it is considered to be a controllable defect; if any of the four points above cannot be satisfied or Failure of a material condition such as equipment, tooling, testing, and materials in production may cause a malfunction. That is the responsibility of the manager. Only by understanding the responsibilities of quality issues can we focus on improving problems and improving quality. bearing steel

Sixth, establish a continuous awareness of quality

Quality is not the best, only better; quality improvement is a continuous, continuous improvement process, it follows the PDCA model, PDCA model can be briefly described as follows:

P-plan: develop improvement plans based on product requirements;
D—Implementation: implementation plan;
C-check: According to product requirements, the process and product inspection;
A—Disposal: Take measures to continuously improve product quality.

Only in this way will the quality of our products continue to rise. Only by continuously improving quality and innovation will we continue to win over the market. bearing steel

Seventh, establish quality cost awareness (ie quality standard awareness)

Guaranteeing quality and pursuing profits are always our goals. In order to develop, enterprises must pay attention to the cost of production. However, cost and quality are closely related. If quality is done well, the cost of the product can be reduced to a minimum. If the quality of the product is not good, the customer will often receive a complaint for return, then his cost will be It will remain high and even push companies into desperation. A lot of reasons for the decline of enterprises: not because there is no customer, no orders, but because the internal management of the company is not good, the cost can not fall down and can not participate in market competition, companies should take warning.

However, the more stringent the quality is, the better it is for the company. On the contrary, excessively improving product quality will result in excess quality and also increase production costs. Therefore, in production, we require that all processes and links be strictly conducted in accordance with customer standards, so that we can minimize costs and improve market competitive advantage. bearing steel

Eighth, establish a quality education awareness

With the development of the times, the concept of quality management is constantly updated and needs to be learned. Successful enterprises in the 21st century will belong to those learning and growing companies. Strengthening internal training and improving the innovative capabilities of all employees will make companies thrive and change with each passing day. Therefore, “Quality begins with education and finally education.” It turns out that those successful companies strictly follow the concept of “products are produced”. They strictly control every aspect of product production and guarantee every one of them. The quality of the link is not wrong, and the link is closely linked, so that the product produced is a qualified good product that can stand the test of the market.

The details determine the success or failure, attitude is everything, only by establishing a strong sense of quality, excellence in quality, persistent pursuit, can we do a good job of quality, in order to take the quality to a new height, to go higher and further。 bearing steel

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