Dealing with subpar components from a supplier. Can you salvage quality control in automotive manufacturing?

The issues related to component quality can be controlled but not eliminated, similar to how we do pest control in our homes. When I was in the plant, we received the spark plugs in opposite directions inside the packing box, affecting their spark gap. We had to use filler gauges and check each spark plug individually, requiring much time. When we raised this issue, about 2 months later, the problem started to get resolved as the component supply came from Germany considering the transportation time too. This experience teaches us that identifying and addressing issues in the supply chain takes time before we start seeing positive results.

Preliminary audit is definitely useful to capture the nature of defect A. Defects attributable to poor raw material quality. B. Defects attributable to manufacturing processes. C. Inherent design defect. Further initial audit findings will play key role is identifying the correct measures to resolve the issues and streamlining the manufacturing and QC processes.

Managing quality control in automotive manufacturing when encountering substandard components from a supplier is crucial. The following steps can be taken to mitigate the impact of such challenges: 1. Clear communication & quality requirements with the supplier 2. Supplier evaluation & rating system 3. Formal quality agreements 4. Rigorous incoming inspection process 5. Non-conformance management process 6. Continuous improvement & scrutiny of quality data 7. Collaboration with suppliers to address quality issues 8. Training and support for suppliers These strategies can salvage quality control and ensure consistent delivery of high-quality components from suppliers in automotive manufacturing.

This doesn’t have anything to do with automotive parts, but it is still relevant. We were performing fluid flow experiments with a heme substitute. This fluid was “certified” equal viscosity to human blood by the manufacturer. The fluid flow values, and pressure readings at bends weren’t jiving. We had just installed a new Rheometer and decided to test the liquid to verify it. Eureka! The viscosity was way too high, and our fluid experimental values now made sense. Having the appropriate testing equipment, personnel, and scientific background is essential. The business side of companies need to stop cutting their lab testing. We obtained a proper replacement from the manufacturer. lesson; Trust but verify.

Quality Assurance determines whether the end products meets the customer specific requirements or as per the applicable standards through a systematic methodology. Data pertaining to Different product Parameters tested for a product of various batches over a period of time during QA stages helps in understanding the Variations in product Parameters that could be due to the manufacturing processes. The key is to control the variability of Parameters within stringent level so as to meet customer specific requirement and it also helps in streamlining the manufacturing process wherein all products have similar Parameters. Advanced QC improvement techniques like Six Sigma and other models helps in streamlining the processes.

Past failures and resolutions adopted helps in overcoming future challenges. Specifying Stringent criteria for approving a sub vendor/ supplier may help in reducing defects in components and completing project schedule on time. Quality is a continous process and scope of improvement is always there.

Je valide du 1er chapitre au 7ème sans problème. Juste si je peux me permettre , la Qualité est quelque chose de complexe et il faut toujours être très vigilants surtout avec les fournisseurs .

The methodology or models used to streamline manufacturing processes may be discussed in details. Since the challenge lies with making identical conponents with all Parameters within the Stringent tolerable limits. Various tools , methods adopted, employee engagement , training needs, usage of advanced machinery and lean manufacturing methods may be discussed.

Share Specifications: Provide clear product specifications to the supplier that must be met. Check Compliance: If the product doesn’t meet these specifications, assess whether it can still be used. Take Action: Depending on the severity: If the product is usable, segregate it for specific use and negotiate a cost deduction with the supplier. If the product is unusable, ask the supplier to replace the entire lot. Joint Investigation: In both cases, work together with the supplier to investigate the issue and find out what went wrong. This approach ensures that issues are addressed collaboratively and fairly