Getting Export Ready!
5 Steps that will make you move towards a more quality oriented and customer appreciated manufacturer.
The domestic manufacturing industry faces a novel challenge today. The big companies are now looking at smaller, less lucrative market segments and there’s fresh competition from new and existing players. Apart from their deep pockets, multinationals now have the latest weapon in their arsenal – Data.
Data allows them to reduce their workforce, increase production levels, reduce downtime and rejections, and find patterns of failure. They use predictive analytics to foresee problems, they use data mining to make business decisions, and they expect higher quality levels from their vendors. Following in the same footsteps, several Indian manufacturers with eyes on global markets have started taking steps to become competitive on a global scale. So what does it take to ensure that you can compete and work towards this goal? Here are five steps our customers have taken to ensure they stay relevant without compromising on their profits or topline in the long run.
Start capturing Data
Data is the new fuel and it is of utmost importance to track your production data. The inability to rely on and make data driven decisions is the prime differentiator between an MNC and a small manufacturer. Identifying problems only at the final stages of inspection, facing delays in production due to machine breakdown are no more an option, especially when it could cost you a customer. Capturing data accurately and timely is one thing, but getting real time analytics from it is the real deal when it comes to beating competition. But does that mean you need to invest in the million dollar shop floor setups that other companies have? Not really. The market has several tools that enable you to shift to a data driven production unit immediately. Our customers offer rave reviews of how their teams are able to handle almost all quality related issues from the comfort of a mobile or a tablet.
Empower your quality department
All manufacturers with critical components being manufactured have a quality department which deploys inspectors on the shop floor to ensure stage production quality. What we have observed, however, is that over time, these inspectors are more busy doing mundane repetitive paper work, and quality management becomes more of a compliance than a function. The job of the inspector deviates towards preparing reports and paperwork, helping with auditors’ queries or correcting issues after production has halted due to rejections, which directly contradicts the core function of the role – ensuring a controlled defect free production.
This needs to change. The quality department needs to be empowered with tools that help them move around the shop floor freely, look at high quality graphs and analytics in real time, and make on the spot decisions when needed.
Rejection – that one dreaded word that is surely bound to make you feel disappointed. The loss of machine and man hours, generation of scrap and production of sub standard products is a reality in most factories. Yet, no one wants a high rejection rate. But as tough as it might sound, dealing with rejection is not as difficult. The key lies in using the right approach. But being consistent in data capture, and identifying issues using data, companies can use data driven decision making and Pareto analysis to focus on issues that really matter. A solution which thrives to assist in managing quality, ensuring a reduction in rejection and thus, cost of quality is the way to go.
Keep your tools calibrated
A measurement system is as good as its current calibrated state. A well calibrated instrument is key to accurate measurements. Accurate measurements give you the real insight into what’s really going on. While most companies still track instrument calibration frequency using stickers and excel sheets, the lapses in calibration generally go unnoticed. If you have experienced this before, it’s probably a good time to check how often these calibrations are being done late. In a process line, while working with several instruments, an inspector/operator is bound to miss out on timely calibration of some instruments. This might be a genuine mistake, but it will directly affect your process control, not to mention the increased cost of rework, false rejections/acceptances, possible damage to equipment, etc. What if you could simply plan these calibrations just once, and get reminded on every due date? Wouldn’t it be easier to have a reminder for each instrument based on their calibration cycle?
Preventive Machine maintenance
All machines can break and it is important that we proactively monitor these breakdowns. Machines are possibly the most critical aspect of your shop floor, yet more often than not, the most disregarded. They need regular maintenance and timely upkeep. With time, they show a pattern of problems that can be identified and worked on. Preventive maintenance is key to ensuring that your operations are not affected by the very investments you rely on, your machines. However, more often than not, machine repairs are a follow up to breakdowns, that result in high repair costs, loss of profits and production, and wasted man hours. A proper machine maintenance plan, along with documenting each breakdown, and possibly identifying major failures would go a long way in ensuring a low downtime production setup.
So how do our customers do it?
Qoti was designed from day one to focus and solve each of these problems. We literally sat and worked n the shop floor of various industries, both domestic and export suppliers, to identify potential problems and come up with smart solutions. Your very own quality management solution, an easy to use mobile application that brings a reduction in your cost of quality and rejection within weeks of implementation.
Our users love how we’ve automated their quality departments, with reminders for all major occasions, tracking delays, issuing alerts for red flags and resulting in direct savings and benefits to the company.
They have been able to reduce the time spent by inspectors in redundant daily jobs by as much as 40%, allowing them to spend more time in actively contributing towards better product quality.
If you’re interested in Qoti, you can request a demo for your company.