What To Do When Production Has Already Started But Problems Keep Appearing

What should you do when production is already underway, but quality problems keep appearing from one shipment to the next?

In episode 336, Adrian and Renaud answer a listener question from David B. and explain how buyers should investigate recurring production problems before deciding whether to fix the situation or transfer manufacturing elsewhere.

They begin by separating product design problems from manufacturing and workmanship issues. A product that cannot withstand normal use may be fundamentally under-designed, while products arriving dead on arrival are more likely to indicate manufacturing failures.

The discussion also covers reliability testing, pilot production, supplier audits, corrective action plans, containment measures, documented process changes, fixtures and mistake-proofing.

Renaud explains why inspections can provide useful short-term protection but should not become a permanent substitute for a functioning supplier quality system. If repeated mistakes continue, records are unavailable, or production is being moved between facilities without your knowledge, it may be time to walk away.

You will learn:

• How to distinguish design failures from manufacturing problems
• When early production issues may be understandable
• The warning signs that a supplier has no effective systems
• What evidence to request after a supplier claims a problem is fixed
• Why corrective action and inspection must be used together
• When transferring production becomes the safest option

 

Show Sections

• 00:00:13 – Introduction
• 00:00:59 – What to do when production problems keep appearing
• 00:02:14 – Design failures versus manufacturing problems
• 00:04:40 – Validating a new product before scaling up
• 00:07:00 – Problems during new product introduction
• 00:08:29 – When repeated mistakes mean it is time to walk away
• 00:10:15 – Using supplier audits to reduce risk
• 00:12:38 – Proving that a production problem has been fixed
• 00:15:38 – Fixtures, mistake-proofing and process improvement
• 00:19:09 – Corrective action versus more inspections
• 00:21:37 – When inspections become supplier babysitting
• 00:23:12 – Common weaknesses to investigate in the factory
• 00:24:58 – Conclusion

 

Related content

• When and Why a Product Failure Analysis is Required
• QC During NPI: Build Quality In Before Mass Production
• Corrective Actions and Preventive Actions (CAPA) Guide
• Production Transfer: A Roadmap (Assembly Operations Only)
• Use a Corrective Action Plan After a Failed Inspection
• Supplier Quality Management: KPIs and Improvement Tools

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