Production Control Systems and Quality Improvement
We are all in the quality business. Wasted time, scrapped materials and customer turnbacks reduce margins and damage our reputations. It’s only by putting the proper systems in place that our shops can achieve maximum efficiency and profitability.
With your existing production control system (PCS) and these five easy steps, your business can eliminate scrap and accelerate production in a matter of weeks.
- Review Non-Conformance Issues Daily
Evaluate your previous day’s non-conformances in your morning production meeting. One competitive advantage your PCS provides is access to real-time production data. Don’t let your team revert back to weekly updates. Keep your processes as agile as your operators. You have all the data you need at your fingertips; use it.
- Monitor Quality Throughout Live Production
Leverage buy-offs and tolerance checks at critical points throughout production. Stop non-conformances in their tracks with your Production Control System’s quality gates. If a check fails or a measurement is marked out of tolerance, use your PCS’s real-time alerts to notify the right team member to resolve the issue and keep production running. If you expect to increase both production velocity and quality rates, it’s essential that you monitor quality throughout production, not just at the end of the line.
- Properly Schedule Machine Maintenance and Tool Calibration
Update and expand your machine maintenance program with digital control. Schedule more frequent maintenance to limit disruption or implement your PCS’s asset management capacity to track usage rates. Why risk falling out of compliance on a run when you have all of the tools you need in one system? Guarantee your customers that every operator, asset and machine is certified for its role in production.
- Create Standard Workaround and Rework Paths
Plan standard workaround and rework paths to maintain production velocity when problems occur. Your ERP is an essential tool for running your business, but your Production Control System shines when production doesn’t go as planned. Take advantage of your PCS’s ability to map proactive solutions to problems from the common to the critical and resolve production issues before they have the chance to disrupt ship dates.
- Review Reports and Trend Analysis to Identify and Resolve Errors
This is why you invested in a Production Control System in the first place. Successful shops require the visibility to track and control production with the agility to handle even the most complex of processes. Use reports and trend analysis to identify the source of common errors, and then utilize process control to eliminate errors in the future. Take control of your shop, eliminate scrap and deliver your customers the highest quality product available.