Question

You have joined a company as the quality executive. The method of quality control is based on the use of total inspections at the end of the production cycle which often results in 15% rework or repairs.
Outline your plan of action for improvement over the first 12 months.

Answer 1

Ans

The current practice of quality checking is to check the total inspection at the end of the production cycle which results in 15% rework or repair which is very high. Such high levels of rework increases cost due to rework cost as well poor productivity. I will use my experience of Six Sigma to bring down this rework percentage. I will make this as a top priority project with the objective of bringing down the rework to 3% of the production cycle. I will define the steps of six sigma in the following ways and with the timelines:

Define: Define the problem in terms of percentage of defect per 1000 units of production. To be completed in 1 month.

Measure: Measure the various types of defects happening . To be completed in 2 months

Analyze: Analyze the root causes of the defects by why-why analysis and fish bone analysis. Make Pareto chart of the defects and its impact. To be completed in 2 months

Improve: Suggest recommendations and execute the same for each of the core defect issues. To be completed in 1 month

Control: Regular monitoring of the process and using Control Charts to monitor the product efficiency in terms of defects produced per 1000 defects. To be completed in 6 months time.