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You are here: Home / Process Improvement / What should factory operators do when defects are found?

What should factory operators do when defects are found?

February 22, 2013

Process ImprovementA few months ago, I drew a flow chart for buyers to follow when a problem is detected during an in-process inspection.

But the very best would be for factory operators themselves to notice defects and to solve the problem immediately, right?

I just found an excellent flow chart that addresses this purpose:

Defect decision tree

Source: “Cedar Works” case study, Becoming Lean: Inside Stories of U.S. Manufacturers, edited by Jeffrey Liker.

Unfortunately, it only works if line workers are allowed to stop the line when defects are noticed. In the world of exporting manufacturers in China, nobody can even imagine that happening. The priority is to “push production out the door”.

And there is a dedicated final QC section, just before the packing stage. Why would line workers, who are generally paid by the piece, bother with defects coming from an upstream process?

Filed Under: Process Improvement


Weekly updates for professional importers on better understanding, controlling, and improving manufacturing & supply chain in China.

This is the official blog of Sofeast.com.

This blog is written by Renaud Anjoran, an ASQ Certified Quality Engineer who has been involved in chinese manufacturing since 2005.

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