Dealing with unexpected quality issues in manufacturing. Are you prepared to tackle them head-on?

Also, know the distinction between "trained" and "competent". Everyone can be trained in their line of work, but are they competent enough to run a piece of equipment while understanding the risks and variables.

The key aspects to successfully solving such problems are a systematic approach to root cause analysis, effective change management and agile process improvement methods. The introduction of preventive measures and quality control at each stage of production allows us to minimize risks. However, even with strict control, surprises may occur that require prompt intervention. A culture of openness and collaborative problem solving encourages defects to be identified and corrected quickly. The introduction of technology and data analytics allows you to proactively predict potential problems, reducing the likelihood of their occurrence.

It is always good to have a preventive and proactive plans assuming all failing possible scenarios. Unfortunately, there are some factors that are difficult to predict, therefore to prevent and prepare a response plan. The question is what will you do, when suddenly something went wrong in the production line? Will you stop the line? will you make a short-term fix? or Will you do a problem risk evaluation, rework or let it go?

if you read the news, it seems that our "Safety Quality Culture" is broken in US. Planes and Bridges collapsing, trains derailing, Batteries exploding and I guess very soon the cloud network system will go to the garbage can. There are two patterns: 1 - Most of these issues are happening in the Big and high-tech US companies. 2- These issues are related with Supplier Engagement. There is a tendency in the US to believe that APQP is the American version of NPI or NPD, this tendency is causing a poor Supplier Engagement. The situation gets worst to the point to "remotely or virtually control the suppliers performance", These companies believe that APQP will prevent all failures. So, there is no need to visit suppliers anymore. Go figure...

Quality personnel and management often chase the wrong underlying causes and don’t know what the real root cause was. Look at longer shifts, mandatory overtime, and micromanagement are all stressors that affect employees. You want less errors focus on morale and actually treat workers like they belong. There is a huge disconnect in the workplace

As Technology advances, there are more tools, equipment and software to control the performance of a production or assembly line either in your own production lines or suppliers. Now, smart factories will develop their own "customized tools and software" according their needs and not depend on tools and software found in the market that are made by people that has no experience in manufacturing.

False, if the data is interpreted by someone that barely knows the process and has no manufacturing experience, there is huge potential for misinformation and misinterpretation. I see it daily and it’s only getting worse.

Yes I’m prepared to tackle them. But I’m not. We have more management positions than ever, more engineering positions than ever, more interns preparing to join the company and a maintenance group that lacks ability. Management today doesn’t know how to motivate people. From my experience blue collar worker’s are treated like lesser beings while the emphasis is on college degrees. Experience is not valued and it’s not appreciated. There is no reward for going above and beyond and there is no accountability those in higher positions. The culture is so messed up right now that the blue collar are just waiting for management to sink the ship. We tried to care and have had that passion stripped from us through disciplinary actions and threats