Quality is produced not checked. The associates producing the parts need to be accountable for quality. Quality function is to assure & to improve product quality based on customers feedback. Lean techniques, quality alerts, pokayoke & trainings of associates, helps to improve quality with reduced cost.

If quality control (QC) measures are driving up production costs, a shift towards a quality assurance (QA) approach can help manage costs while maintaining high product standards. QA emphasizes preventing defects through process improvement and proactive measures, reducing reliance on costly QC practices like extensive inspection or rework. Here's how you can effectively integrate QA to balance costs and quality: • Focus on Process Optimization • Enhance Employee Training • Design Quality Into the Product • Continuous Improvement • Leverage Technology QA reduces defects at the source, minimizing the need for QC interventions. Instead of eliminating QC entirely. Use QA to prevent defects and enhance process capability.

1. Streamline Quality Control Processes Automate Inspections: Invest in automation for repetitive quality checks. Automated systems can reduce labor costs, minimize human error, and speed up the inspection process. 2. Risk-Based Quality Control : Focus on high-risk or high-impact areas where defects could cause significant problems. 3. Invest in Training and Employee Empowerment Skilled Workforce: Well-trained employees can identify and address quality issues early in the production process, reducing rework and scrap costs. 4.Root Cause Analysis: Implement root cause analysis techniques (like Fishbone diagrams, 5 Whys, etc.) to address recurring quality issues, thereby reducing the need for frequent checks and rework.

Here are few techniques which can be inculcated to manage the expenses: 1) Adopt a preventive approach. 2) Automate quality control processes. 3) Implement statistical process control. 4) Involve your suppliers and customers. 5) Train and empower your staff.

Initial approach: Through COPQ analysis to prioritize the most expensive cost incurred in the production line and then take actions to minimize the internal failure. Once all is fixed then we need to focus on high appraisal costs to increase the inspection frequency.

- spend enough time for planning of control processes - learn the real and important needs of your customer - use LEAN and industry 4 tools in quality processes - keep the balance between cost of nonconformity (scrap, claims, reworks) and conformity (inspections, preventions)!!! - don’t afraid of asking for deviation release (find the real needs of your customer) instead of producing over quality during entire lifetime - perform continuous risk assessment

I think make the pareto chart for selected the most issue on quality control can manage about priority job and priority cost.

1. Show the Manufacturing team what this actually means and how it affects the bottom line. Good Team members want to produce quality products. 2. Hold Quality circles/events and make sure they are cross functional with the right people to help. i.e. Engineering, Programming, Gage/Fixture Design and Operations performing the job 3. Provide the team with the tools they need to make improvements.

Quality ultimately is dictated by the design of the product. The design should incorporate the easiest to manufacture processes and put all of the important design characteristics in highly controlled processes that are automated. A poor design relies on GREAT processes to make it work. A great design uses the least amount of process control and get the desired outcome.