CNC Machining and CNC Machine Tools, Manufacturing Processes and Procedures

Product quality is production, designed out

Introduction: Product quality is produced, not tested, only in every step of the production process, in strict accordance with the requirements of the production process and operating instructions, in order to ensure product quality. metal prototype fabrication

However, the topic “Quality is produced or tested” has always been the focus of debate in the business community: Producers say quality is tested, and inferior products flow into the market; inspectors do not have a good relationship; inspectors say that quality is Produced, if the manufacturer does not produce defective products, there will be no inferior products on the market! 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:


To allow a handful of bad, unexpected flaws is unavoidable;
Quality is the responsibility of the quality control department;
Only emphasis on product testing, inspectors need to be responsible for resolving defective products;
If something goes wrong, it feels like a quality department. metal prototype fabrication

I think a lot of friends to do quality work, have more or less had such feelings. Often when writing a report, the quality department is completed by 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, often said a few words, and it should be flashed.

So, product quality in the end is produced or tested out?

First of all, we have to analyze the relationship between initiative and passive. As we all know, the product is produced first and the test is later. In other words, only if 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 the post-mortem check, but must be placed in the manufacturing phase, that is, the production process. metal prototype fabrication

First, why is there a quality problem?

Before the product development, the problem is not handled properly, and the mass production pass rate is too low. We hope to rely on the quality of firefighting. We want to improve the frequency of detection and reduce the defective products or unqualified products. Adding the rework materials and unqualified materials, we haven’t passed through beforehand. Test and verification, there is no accurate knowledge of product quality fluctuations; customers push for goods, pressure on the top, the boss according to their own so-called practical experience to speak, 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…

Second, 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 of the raw materials had black spots, which caused the products to fail and caused huge losses. metal prototype fabrication

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. The final result, hundreds of tons of orders, because of such a quality problem, yellow. Fortunately, the user did not produce the film and it was really unthinkable.

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. metal prototype fabrication

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. Quality control is required at every step of the quality management system, and these controls are obviously not fully borne by the quality inspection or quality management departments. These controls must be implemented by the people in the best position. 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. metal prototype fabrication

Third, how to fully control the quality of products
The product is basically positioned in the design stage, and then the quality is guaranteed by purchasing, processing, manufacturing, packaging, and transportation. The control of these links is good, and the 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:

Establishing quality is the lifeblood of enterprises
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 are in full bloom, the breeze comes.”

Establish 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. metal prototype fabrication

Establish a quality awareness of 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 generated from the source control during 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. metal prototype fabrication

Establish a quality program awareness
Quality management is the whole process and company-wide. The work between all 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 chances of mistakes will increase, the quality of the product can not be guaranteed.

Establishing 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:

The operator knows what he did and why he did it;
The operator knows if the product he produces meets the specifications. metal prototype fabrication
The operator knows what the consequences will be if the product he produces does not meet the specifications;
The operator has the ability to correctly handle anomalies.

If the above four points have all been met 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 can 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.

Establish a continuous awareness of quality
Quality is not the best, only better; quality improvement is a continuous, continuous improvement process that follows the PDCA model. metal prototype fabrication


The PDCA mode can be briefly described as follows:

P-plan: develop improvement plans based on the requirements of the product;
D—Implementation: implementation plan;
C-inspection: 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.

Establish quality cost awareness
(ie, awareness of quality standards)
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 the quality is done well, the cost of the product can be minimized. If the quality of the product is not good, the customer will often receive a complaint from the customer, so the cost will be Will be high, and even forced the business desperate. 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. metal prototype fabrication

But the quality is not more strict on the business more favorable. 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.

Establish a quality of educational 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 who learn to grow up, strengthen internal training, and improve the innovative capabilities of all employees, which will make the company prosper 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 ensure that each 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. metal prototype fabrication

The details determine the success or failure, and the attitude determines everything. Only by establishing superior quality consciousness, striving for excellence in quality, perseveringly and steadfastly in pursuit of quality, can quality be raised to a new height, and can go higher and further. metal prototype fabrication

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