Temporary Change of Process Control as per IATF 16949 |Complete Guide

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Temporary change of process control

In automotive manufacturing, production processes are designed with defined controls to ensure consistent product quality. However, situations may arise where the primary process control becomes unavailable or ineffective due to equipment failure, tool damage, gauge breakdown, manpower issues, or other unexpected conditions. In such cases, organizations must implement a controlled temporary solution to maintain product … Read more

Statistical Process Control (SPC): Complete Guide & Examples

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SPC

What is Statistical Process Control (SPC)? Statistical Process Control (SPC) is a method of monitoring and controlling a manufacturing or service process using statistical techniques. It helps identify variations, detect problems early, and ensure consistent product quality. SPC primarily uses control charts to distinguish between normal process variation and abnormal variation caused by specific issues … Read more

How Lean Methodology Identifies Waste in Processes?

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Lean methodology

In today’s highly competitive manufacturing and service environment, organizations must deliver maximum value to customers while minimizing costs, delays, and inefficiencies. Lean methodology provides a powerful framework to achieve this by systematically identifying and eliminating waste in processes. Originating from the Toyota Production System (TPS), Lean focuses on creating more value with fewer resources. Understanding … Read more

Tool, Fixture & Gauge Maintenance Procedure in Manufacturing

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Tool Maintenance

Tools, fixture & gauges are critical assets in any manufacturing organization. Their condition directly affects product quality, dimensional accuracy, productivity, and customer satisfaction. Poor maintenance can lead to defects, rework, downtime, safety risks, and audit non-conformities. This article provides a complete, practical, and ISO/IATF-aligned procedure for tool, fixture, and gauge maintenance, including preventive maintenance planning, … Read more

Root Cause Analysis (RCA):Methods, Tools & Examples

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Root Cause Analysis

Root Cause Analysis (RCA) is a systematic problem-solving method used to identify the underlying cause of a defect, failure, incident, or nonconformity so that it does not recur. Instead of treating symptoms, RCA focuses on eliminating the fundamental cause of the problem. RCA is widely used in quality management, manufacturing, engineering, healthcare, IT, safety investigations, … Read more

Pareto Chart Explained: 80/20 Rule, Example & How to Create in Excel

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Pareto Chart

A Pareto Chart is one of the 7 Basic Quality Tools used to identify the most significant factors in a problem. It is based on the Pareto Principle (80/20 Rule), which states that roughly 80% of effects come from 20% of causes. This chart helps organizations focus on the “vital few” issues that create the … Read more

Benefits of 7 QC Tools (Basic Tools) in Quality Management

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Benefits of 7QC tools

The 7 QC Tools, also known as the Seven Basic Quality Tools, are fundamental problem-solving techniques used to control, analyze, and improve processes. These tools are widely applied in manufacturing, automotive, aerospace, healthcare, service industries, and project management to reduce defects, improve efficiency, and support data-driven decision-making. In ISO 9001 and IATF 16949 environments, the … Read more

Value Added vs Non-Value Added Activities: (Lean Guide)

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Value added activities

In Lean manufacturing and quality management, every activity performed in a process is classified as either value added or non-value added based on whether it contributes to what the customer is willing to pay for. Identifying and eliminating non-value added activities helps organizations reduce waste, improve productivity, lower costs, and shorten delivery time. This concept … Read more

What is a Tree Diagram? Definition, Steps & Example (New 7 QC Tools)

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Tree diagram

A Tree Diagram is one of the New 7 Quality Management and Planning Tools used to break down a broad objective into smaller, manageable tasks. It helps organizations move from a general goal to specific actionable steps in a logical and structured way. In quality management systems such as ISO 9001, IATF 16949, Lean Manufacturing, … Read more

Process Audit & Product Audit explained with latest checklist

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Product & Process Audit

Product and process audits are essential quality assurance tools used across manufacturing industries, especially in automotive OEMs, Tier 1 & Tier 2 suppliers. These audits verify whether processes follow the defined standards and whether the final product meets customer requirements. In the automotive sector governed by IATF 16949, both process audits and product audits play … Read more