5 quick factory quality tips
November 24, 2009 by Thuy
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We noticed recently customer unease at some factory practices. Would they have an impact on quality? A third party Quality audit sets things straight by providing an independent first-hand account from the factory floor.
Below are 5 simple tips to follow when you walk into a factory:
Scan space
- Is the space clean, well ventilated, well lit and well kept?
- Are the work and storage areas well separated?
- Is inventory clearly labelled, indicating its status?
- Are there areas for product storage between work areas? If yes are they well delimited? Is there any sign of check for product compliance in these areas?
- The more transparent work and product flows (and not just with labels in English for your benefit), the lesser the risk of mistakes by people who work in the factory because common sense will be used.
Observe workers
- Is their organisation understandable to you? Where are the team leaders?
- Are there signs of rushing, dropping things, discipline? We have seen line workers horsing about / wrestling in multibillion dollar factories when the line manager is not around. What does that say about their respect for the organisation or product.
- In larger factories, is a quality team present and easily identifiable by badge, uniform?
- In Chinese factories, check the dormitory and kitchen for cleanliness.
Query management
- Is Quality part of the duties of the line manager, or is Quality run as a separate department, as it should be?
- If the factory is ISO9001 certified, then express a concern about the quality of an incoming component, and ask to see the incoming quality control records. Drill down to be sure you are shown a number of reports. Ask how the sampling is done, how the product quality criteria are set, by whom and see evidence of any explanation.
- If possible discreetly find out if workers are paid by the piece or the hour or month, as workers paid by the piece will tend to play fast and loose. We have no preference for one or the other system, but know that piece rate + no separate quality team means trouble.
Question traceability and learning capabilities
- Does the factory use an Enterprise Resource Planning system (ERP)? This allows traceability.
- If there is an ERP, is it a single computer in an office (so much for the “enterprise” idea) or are workstations available in the warehouse and factory floor for line managers to access?
- Can the factory show records to link a piece to work, date, status, materials used, perhaps even work team on the date and individual workers?
- Are records consistent with product and materials labelling?
- Check for defect analysis records and actions taken to remedy problems (change work process, additional training, information sharing). This includes not only products, but also simple checks for machine maintenance records, if the factory uses complex equipment. These are usually displayed near the equipment.
Ask for defective goods
- Ask to see defective goods storage and handling records
- A factory that never has any defective goods or defective goods records is bad news.
- All their suppliers would always provide perfect products and they would never make a mistake themselves… right…
Actions:
- No direct actions, just a simple check list to keep in mind for your next factory visit
- If you have any doubts and do not have the time, the Asquance team is of course available to conduct an audit for you!