Such situations Go through PFMEA approach and find the gap of detection and prevention levels. If detection level are less than four than only introduce Poka yoke audit. If more than four then ensure your team members are trained and give awareness to them about criticality of process and operation. Also guid to each team members about they should be performed and check visual CRP. C : Clamping, R : Resting, P : Process. to avoid parts skipped from station if there are any abnormalities. Thanks

Automate & Streamline: Use automation for consistent dough handling and shaping. Standardize Ingredients: Source high-quality ingredients and set clear quality specs. Real-Time Monitoring: Regularly check dough, proofing, and baking to ensure consistency. Employee Training: Keep staff trained and engaged in quality-focused practices. Final Inspections: Conduct quality checks before packaging and shipping. Maintain Equipment: Regularly service machines to avoid disruptions.

Here are some key strategies to consider: 1. Hire and retain top talent through a continuous recruitment process 2. Invest in automation to streamline processes and improve efficiency 3. Clearly communicate the company's vision, mission, and purpose to all employees 4. Implement standardized procedures to prevent defects and ensure consistent quality 5. Protect and retain core employees 6. Develop a strong leadership team setting the tone of org. 7. Avoid overextending resources by managing load for quality 8. Document company & dept. Key Performance Indicators - KPIs 9. Regularly review financial equations 10. Empower frontline decision - makers to act swiftly 11. Provide comprehensive training to customer-facing teams

Measure and analyze the process input variables. Measuring only the quality standard of the output is a blind push towards a goal. Measuring the input variables give you insight about the causes of variations to the process. Implement real-time monitoring systems. Listen to your data.

Multi skilling is always the key to be prepared for that growth, this allows your workforce to understand the whole value chain.

To ensure quality standards consider the following points: 1. Standard Operating Procedures (SOPs):Establish clear and detailed SOPs for each process to maintain consistency. 2. Training and Development: Provide regular training for employees to ensure they understand quality standards and best practices. 3. Quality Control Inspections: Implement regular inspections at various stages of production to catch defects early. 4. Use of Technology:Employ automated quality monitoring systems to detect issues in real-time. 5.Feedback Mechanisms:Create channels for employees to report quality concerns and suggestions for improvement. 6.Data Analysis:Use data analytics to monitor quality trends and identify areas for improvement.

Lo primero es estandarizar los procedimientos. Luego, usar tecnología como automatización y controles de calidad automáticos ayuda a minimizar errores humanos. Es vital capacitar al personal constantemente, especialmente con nuevos equipos o técnicas. Revisar el flujo de trabajo y asegurar que las máquinas estén en buen estado mediante mantenimiento preventivo. Controlar la calidad de las materias primas también es esencial. Implementar controles de calidad a lo largo del proceso y no solo al final permite corregir errores antes de que se acumulen. Usa herramientas de análisis para detectar problemas recurrentes y mejorar continuamente el proceso, junto con un sistema de retroalimentación rápida para corregir fallos en tiempo real.

One thing i have found helpful is continuous training so that each Member of the production team is as conscious about quality as the 'Quality' team. It takes time. It seems best not to wait for high demand.

Se debe enfocar en las no conformidades detectadas en corridas previas, con el fin de que no se presenten. Prestar atención a subprocesos que se puedan implementar para hacer más agil el flujo del proceso, ya que en estos pueden ocurrir defectos al poder efectuarlos previos al ensamble final.

Precision product fixturing/handling and automation/robotics to ensure reliable repeatability is a must. Additionally, a robust controls platform having a proper AI driven vision system and other data acquisition measurement systems fed back to the central processing system for real time performance and maintenance check system metrics and prevent downtime. #salemautomation #custommachinebuilds #automation