Poison test for quality inspectors in manufacturing industry

Poison test

What is a Poison Test? A poison test is a process of checking the competence of quality inspectors. It is done by providing a small mixed lot of OK and defective parts for inspection within the defined takt time. It is a periodic practical process of taking tests for final inspectors. Poison tests, also called … Read more

What are cycle time and takt time in lean manufacturing?

cycle time vs takt time

Cycle Time vs Takt Time: Cycle Time: Cycle time in manufacturing is the time taken to produce a final part using different processes. It is a time-consuming process that takes the maximum time. We can get cycle time by observing the process for a defined time and counting the number of parts produced. We should … Read more

What is the Cost of poor quality and how to calculate COPQ in the automotive industry?

COPQ

Cost of Poor Quality: The cost incurred in producing & rectifying a defect is called the cost of poor quality. It is also called the cost of non-conformance. Purpose of COPQ: The cost of poor quality will be calculated for all rejections and rework at the in-house and customer ends. The MR/QA head will be … Read more

What is the inventory turnover ratio and the number of days inventory

Inventory Turnover Ratio

Inventory Turnover: Inventory turnover is the rate at which a company converts its inventory into sales. It is the number of times a company makes the sale of its inventory in a period. Where inventory is the total of all goods in its stock, which includes Raw materials, bought-out parts, Work in progress and finished … Read more

How do supplier selection in the automotive industry?

Supplier Selection

Purpose:  To implement a system for supplier evaluation, supplier selection, and supplier approval based on their ability to supply products as per the company’s requirements. Scope:  It covers all materials, parts/components, job work & direct production consumables whose products/services affect end-product quality. Responsibility of Supplier Selection: The purchase Head is the overall responsible person for … Read more

New management review check points as per IATF standard

Management review

Management review of the organization’s QMS at planned intervals will be done by top management. Management review is done to ensure the continuing suitability, adequacy, effectiveness and alignment with the strategic direction of the organization. Input/checkpoints to be discussed during MRM: Below is the IATF Management Review Checklist: 1. Status of actions from previous management … Read more

Steps of PPAP during new development | Production part approval process

The Production Part Approval Process (PPAP) is a core requirement in the automotive supply chain, ensuring that every new or modified part meets customer expectations before mass production begins. This standardized process verifies design records, process capability, and quality controls through 19 key elements and five submission levels. By following PPAP, organizations can minimize risks, … Read more

Procedure for machine maintenance in manufacturing industry

machine maintenance

Purpose: The purpose of this machine maintenance procedure is to explain and understand the steps of attending to machines for maintenance. Scope: Responsibility: The maintenance in-charge is responsible for all the activities on time. Procedure: Master list of machines: Identification of the machine: Preventive maintenance of machines: Daily machine check sheet: It is a machine … Read more

Kobetsu Kaizen in manufacturing with TPM

Kobetsu Kaizen

What is Kobetsu Kaizen? Kobetsu Kaizen, which translates to “focused improvement” is a continuous improvement strategy to make incremental changes to specific processes or machines. It emphasizes eliminating waste, reducing cycle time, improving quality and boosting productivity. Kobetsu Kaizen is a Japanese term that means Targeted Improvement or Focused Improvement. It is one of the … Read more