Você se depara com um cliente que exige uma produção mais rápida. Como você garante que o controle de qualidade não seja comprometido?

Meeting client demands for faster production while maintaining quality control requires a strategic approach that balances efficiency with rigorous quality standards. By understanding the client’s needs, optimizing production processes, enhancing resource allocation, and maintaining transparent communication, you can achieve both speed and quality. Continuous monitoring, post-production reviews, and a commitment to continuous improvement will help ensure that your production remains both swift and high-quality.

This is another misconception, I came across. Quality is not a building block of production. If addressed committedly, quality can make production faster. If quality is seen as a reason for delay in production, probably the top management needs to recalibrate and equip themselves to make quality work. To cite one example. Assume defects were observed in raw material frequently leading to production delays. There is no effective mechanism to eliminate this reason. If properly addressed, such incidents will not only be eliminated but will leave no chance for any such delay.

By applying lean manufacturing unwanted or extra process need to remove and verify CTQ parameters at frequency of samples and go for smooth production

Algumas estratégias podem ser implementadas: Automatização de Processos: Utilizar ferramentas e tecnologias; Treinamento Contínuo: Garantir que a equipe esteja bem treinada e atualizada; Monitoramento Constante: Implementar sistemas de monitoramento em tempo real; Auditorias Regulares: Realizar auditorias de qualidade frequentes para garantir que os padrões estão sendo mantidos. Feedback e Melhoria Contínua: Coletar feedback regularmente e usar essas informações para melhorar processos e produtos. Gestão de Recursos: Assegurar que os recursos necessários (materiais, equipamentos, pessoal) estejam disponíveis e em boas condições para evitar atrasos e problemas de qualidade.

Es importante revisar si todas los procesos que se aplican durante la fabricación agregan algún valor al producto, a manera de simplificar actividades. Automatizar los procesos críticos y trabajar en las habilidades del personal.

In nutshell to achieve quality product with quantity following steps to be followed, Take control on all 5M condition and ensure inbuilt quality output. Also increase the vigilance and review from skilled team & management team.

Simplifying processes is one of the fastest ways to increase productivity, however, to avoid impacts on quality, it is extremely important that process capacity is maintained, this is the basis of the six sigma concept.

In the Automotive EE domain, processes are mostly streamlined. I am not denying the need for streamlined processes; we must keep improving. The hour needs to establish a seamless process if it is a waterfall approach and ensure that it is followed "spiritually." If it is getting too complicated, rejig the whole process to Agile, Continuous Integration, and Delivery (CI/CD), which ensure focus on quality and, if followed rightly, can deliver faster results.

Consider documenting the standard processes, procedures and policies to ensure that tasks are performed consistently across the organization. This reduces variability in the quality of products or services, leading to more reliable outcomes.

It is not just about investing in technology but also about ensuring it is used correctly and responsibly. The efforts required to get consistent and reliable results from tech like GenAI/AI are great, and if we do not have good data or if available data is not analyzed correctly for the task, the results can be far away from the expected. We stand at risk of putting more skilled manpower to work for a longer time to reduce a few minutes or hours of unskilled manpower. Therefore, select the right technology, look into the current and future needs, and apply responsibly.

Try to apply automation on complex and critical process by which manual occurs more and monitor and verify the results and after that validation automation process for smooth production without disturbing Quality parameters

The primary Tech investment should be on information systems, in line with the lean workflow for easy access to data and monitoring KPI so that priorities are visible and straightforward. The next should be on accessories and tooling to ensure ergonomics and repeatability at each step. Automation depends on the targeted production volume.

You must validate your capability and ensure you have the resourses to support such demand, identify KPI and make sure they are properly measured and validated

Robotics and automation will enhance production output as there will be efficiency in work flow without sacrificing quality requirements .

Implement automation tools to enhance production speed without compromising precision and consistency, adapt existing processes to the demand. Leverage technology to reduce errors and maintain consistent quality.

3 Skilled Workforce A skilled workforce is indispensable for maintaining quality control. When under pressure to increase production speed, ensure that your team is well-trained and aware of the importance of quality. Regular training sessions can keep skills sharp and introduce new techniques that can expedite processes without compromising standards.

The human capital of a company is undoubtedly the most important aspect, investing in training its employees, in addition to increasing productivity and quality, is investing in the professional, cultural and personal development of each employee.

Lo primero que se debe hacer, es entrenar a todo el personal y en todos los niveles, para que la calidad sea un tema continuo. Entre mejor conozca el personal el proceso, el producto y los requerimientos de calidad, más facilmente podrán reaccionar ante un aumento de produccion ( ramp up). Una mano de obra bien entrenada nos aportará las soluciones para hacer el proceso más facil, entenderá los limites del equipo de producción, de medición, lo que eventualmente se traducirá en las mejoras e innovaciones necesarias para mantener el ritmo, sin que decaiga la calidad.

Train operation and working on specific time interval show them what's right and wrong practice and give training on work techniques

Competent and industry informed production staff with periodic training on productivity will enhance required output where everyone is trained that quality control is everyone responsibility.

Make sure the team is trained in handling the product requirements and complexities. Quality should be the team’s number one priority. Ideally, your team should also be trained in efficient production technics and should be well verse on the process methods applicable.

Check material Quality as per product standards requirement and follow First pass yeild and monitor material Quality parameters

Faster production will be achieved when Materials quality are monitored right from procurement processes and delivery . Compliance with Inspection and test requirements . Issuance of materials on time according to the work flow without compromising Quality.

Continue sourcing the same quality grade materials that meet the product’s specifications and customers’s expectations, even under time pressure.

Continuous testing is extremely important, but knowing what type of test, or what type of equipment should be used and the main one, so it is advisable to carry out MSA studies (MEASUREMENT SYSTEM ANALYSIS)

IPI (In process Inspection) to be applied through the manufacturing process. Even with the other presented options, the quality would be assured by samples to be verified per end phase. Would reduce the risk of NC (Non conforming) products to progress on the line and would reduce the waste and increased the final product Yield.

Continuous testing is extremely important, but knowing what type of test, or what type of equipment should be used and the main one, so it is advisable to carry out MSA studies (MEASUREMENT SYSTEM ANALYSIS)

Test points as per inspection and test plan to be strictly followed. All inspection staff to be proactive of process requirements and ensure necessary documentation and sign off points are observed.

Continuous testing in automobile manufacturing ensures quality isn't compromised, even with faster production, by detecting defects early, automating inspections, and providing real time feedback. AI and machine learning analyze testing data to prevent issues, while integration with suppliers maintains part quality. This minimizes rework, ensures compliance with standards, and upholds customer satisfaction, all without slowing down production.

Continuous testing allows for the detection and correction of quality issues throughout the entire process, ensuring that products meet standards even if production has been accelerated. This helps identify defects early and reduces the risk of faulty products reaching the customer. While other options like technology and skilled labor are also helpful, continuous testing is key to maintaining consistent quality under any circumstances.

Conduct regular spot checks during production to catch defects early and ensure compliance with quality benchmarks. If you suspect the process consider also implement rigorous testing throughout production to identify and resolve issues quickly.

A feedback loop in automobile manufacturing ensures quality during faster production by providing real-time data to quickly identify and correct issues, optimize processes, and ensure supplier materials meet standards, all without compromising quality.