Learn About these 3 Quality Control Methods to Achieve Utmost Quality Standards

Highly successful corporations vary their manufacturing SOPs. What they have in common is the use of tried and tested quality control and assurance methods such as six sigma, lean, and kaizen.

In this article, we’re going to talk about the top three manufacturing philosophies and practices. We’ll also give you a viable solution on how you can digitize these practices for your organization. 

1. Six Sigma

Six Sigma is a set of quality management techniques that aim to reduce defects in manufactured products by identifying and removing the root cause of errors. The key to six sigma is its focus on preventing defects rather than simply detecting and correcting them after the fact. 

For instance, a complete in-general  process must have a maximum of 3.4 defects per million opportunities to be considered “Six Sigma Quality.”

Six Sigma Methodologies

Six Sigma employs several methodologies, tools, and techniques, including process mapping, process capability analysis, Design for Six Sigma (DFSS), and statistical process control (SPC).

DMAIC (Define, Measure, Analyze, Improve, Control)

DMAIC is a project management method for improving an existing process. It includes the following phases:

  • Define the problem, what needs to be improved, and how the goals for improvement and customer requirements.
  • Measure key performance metrics.
  • Analyze root causes of poor performance.
  • Improve the process by implementing solutions.
  • Control the process improvement and future process performance.

DMADV (Define, Measure, Analyze, Design, Verify)

DMADV focuses on the process of designing a new product, service, or process and incorporates these phases:

  • Design products that meet customer needs and the organization’s identity.
  • Measure and identify how the product, service, or process impacts quality. This includes risk and production capabilities.
  • Analyze objectives to maximize design.
  • Design, develop, and test the product, service, or process to make it more effective.
  • Verify design through rigorous testing.
Explore Six Sigma Checklists App

2. Lean

Lean manufacturing is a production methodology that emphasizes the reduction of waste in all areas of the manufacturing process. Lean manufacturing methods can be applied to any manufacturing business, regardless of size or industry.

Lean identifies the presence of and eliminates seven specific wastes mentioned below.

  1. Overproduction – Creating more products than is necessary or can be sold
  2. Waiting – Time spent idle waiting for the following process
  3. Transportation – Unnecessary or excessive movement of products
  4. Inventory – Excess or unnecessary inventory
  5. Motion – Unnecessary movement of people or equipment
  6. Defects – Products that do not meet customer expectations
  7. Overprocessing – Applying more resources to a necessary product

Tools

Numerous companies apply Lean principles to their operations. Below are the most widely used tools and techniques for practicing lean.

5S (Sort, Set in Order, Shine, Standardize, Sustain)

5S approach  is a system of organization designed to prevent items from being lost or misplaced. It focuses on prevention to achieve an effective and efficient workplace.
  • Sort – Identify what is necessary or appropriate and discard everything that is not.
  • Set in Order Organize, arrange and store your items, so they are all in their correct places.
  • Shine Have an organized, clean area for safety and inspection.
  • Standardize create a work area with the three steps to create a standardized one.
  • Sustain Make plans to update and maintain the consistency of procedures.

PDCA (Plan, Do, Check, Act)

The PDCA technique takes place in a cycle designed to solve industry-wide problems.

  • Plan: Identify the problem, establish goals and objectives, and develop an action plan.
  • Do: Implement the plan and collect data.
  • Check: Analyze the data to see if the problem has been solved and identify any areas for improvement.
  • Act: Take corrective action as necessary and continue monitoring the situation.

The PDCA cycle can be used for problem-solving, from personal issues to business process improvements. It is a simple yet effective way to help you focus on what needs to be done to reach your goals.

5 Whys

Toyota pioneered multiple manufacturing and management models. These business standards are often found in organizations like 5 Whys. Lean is used to find the root cause of a problem using a technique called 5 Whys.

Lean Manufacturing Audit Checklist App

3. Kaizen

Kaizen is a quality control method that focuses on continuous improvement of all business processes, intending to eliminate wastefulness and increase efficiency. It was developed in Japan following World War II and has since been adopted by businesses worldwide.

Tools

Here are some of the most common Kaizen tools companies use:

SIPOC (Suppliers, Inputs, Process, Outputs, Customers)

SIPOC is a tool for ensuring clarity in process workflows. This helps eliminate redundant efforts and identify where people struggle to complete their duties.

Furthermore, it helps to increase accountability as well as decrease overall efficiency.

Gemba Walk

Performing a Gemba walk is an activity that executives should make part of their routine, as it will ensure that upper management can observe their staff’s processes and identify opportunities for improvement. It also helps ensure that upper managers learn about the actual work rather than simply commenting on individual performance.

We have developed an easy-to-use Gemba walk app for organizations to streamline the Gemba walk process for manufacturing operations. The app helps manufacturers to identify key improvement areas.  Companies can work through Gemba walk checklists to capture first-hand observations, gather information, collect digital notes, and conduct walkthroughs of manufacturing sites & shop floors.

You connect with us here for detailed information about our Gemba Walk App

8D Report

The 8D Report is a problem-solving technique used to contain, resolve, and prevent process issues. The method was initially only used in the automotive industry due to Ford’s influence but is now widely used in various industries, including manufacturing, healthcare, and retail. The strategy includes using experts, data analysis tools, management solutions, and validation of collected data.

Top Ten Kaizen Software of 2022 for Continuous Improvement

Axonator for implementing Quality Control Methodologies

Manufacturing organizations across the globe can use Axonator for digitizing quality control operations like quality audit, quality inspection, and more. Fortune 500 firms have used our no-code platform to ensure high-quality standards of products and services. Our no-code platform has tons of features to ensure that the platform will meet the end goal of the company.

Aside from helping companies in the quality control operations, it can also streamline other processes like inspections, maintenance, audits, compliance, and more.
Numerous industries and organizations use Axonator to automate field workflows, achieving digital transformation in record time and cost.

Why Axonator?

  • World’s first mobile-focused & Highly customizable no-code architecture to support real-world scenarios.
  • Deploy enterprise-grade solutions rapidly as per unique requirements
  • Achieve paperless quality audits and inspections
  • Generate reports automatically and automated data collection for trends and analytics
  • Streamline processes and implement a fully automated system within weeks using Axonator’s MicroApp strategy.
Available on Android, iOS, and the web, Axonator is a highly customizable no-code field workflow automation platform mainly used to transform your paper and spreadsheet-based manual processes and maintain quality control in numerous industries.

Axonator offers several simple and ready-to-use enterprise-grade apps for field workflows like inspections, audits, safety, asset management, and work orders that organizations can use to replace paper, spreadsheet & cumbersome desktop-based manual processes with mobile & tablet apps.

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Article Index

  1. What is Axonator’s MicroApp Strategy?
  2. The Implementation of “The MicroApp Strategy” is Easy
  3.  The Top Benefits of Digital Transformation using the Axonator’s MicroApp Strategy

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