Speaker: Michel Gadbois
The first thing to do as part of a systematic approach to reducing the cost of quality is to initiate a steady stream of kaizen events. A kaizen event is when companies get together all of the people who are participating in a process and have them discuss the process. They discuss what is easy and what is difficult about the process, and they determine how to do it in a more repeatable way. We talked about poka-yoking the process, which is making it so error-proof that whether you are having a good day or a bad day, the part comes out the same. The first thing to do is to put together a steady stream of kaizen events.
Kaizen events help you to do two things:
Identify which part of the process is more difficult physically so that you can improve it.
Find out that the information side of the process is very inefficient.
When we start to identify those inefficiencies, we can start to eliminate them. It will become very obvious that the only way these inefficiencies can be eliminated is for the data coming in to the process to be valid and verifiable. To ensure valid, verifiable data, the engineering definition must be tied to the process definition, and then those definitions must be tied to the execution. If we have a good engineering definition and we have used that definition as a list of parts and list of processes to define a process, and we now track how well we are doing on the shop floor, you have very little place for variation or for mistakes. That means that you can eliminate most of your verifications.