We are in a global economy now. We are in fierce competition with
Mexico and China in the global market place. Where China or Mexico can
afford hgh scrap rates because they have low labor costs. American
companies don't have that luxury. We need to keep our equipment
maintained to produce low scrap yields.
Continuous process improvement using SPC techniques is the best tool
to do this. Anything short of Total Quality Management is "expensive
nonsense." The cost of quality, on average, is around 4%, where the cost
of non-conforming product is roughly 20%, according to Crosby.
My company has already pumped-out nearly a million dollars this year
in sorting costs, this doesn't include overtime internally for
non-conforming parts caught in house. If one were to do a why-why
analysis for this, the root cause would be lack of control over
processes, poorly maintained equipment, high variation within processes,
running 7 days a week, non-stop. I'll ask anyone, if you were to work 10
hour days, 7 days a week, for over a year, how much "Git R Done" do you
think you will have left in you? The cost of non-conformity goes far
deeper than a dollar sign. The associates on the floor get burned-out,
many of the best ones quit. Customers get frustrated as well, they want
smooth running at thier facility, not an army of sorters getting in the
way. Or a 20% spike in leak rates, etc...When the customer has to work
10 hour days, 7 days a week, because of high fallout from your companies
non-conforming goods. I think you can see the cost of quality starts
looking more appealing.
I am not sure exactly what this thread was about, but SPC and
six-sigma isn't "BS"
|
