AsiaQuality Focus (AQF) has found that Production Monitoring (PM) services are more
and more used as a tool for remote management with clients’ factories. PM
Inspections have been designed for 3 categories of need:
·
You want more cooperation with your
factories.
·
You want to anticipate potential QC
issues and have better understanding of your factories.
·
You want to tackle a particular quality
issue.
The difference
between a Production Monitoring and a Pre-shipment inspection is that on a PM,
an inspector comes from two angles. Not only do they focus on your goods and
your order, but also on the basic organization of the factory. But how do you interpret the results of
this service?
1 - Organisation
Although
it doesn’t immediately alleviate your issues, getting one inspector
to look for corporate documents will actually help to get the lay of the
land. Inspectors can seek out organizational documents such as charts, QC
process available for employees, training records, collection records and so
on.
In comparison
with an audit, an inspector performing a PM won’t judge the contents of these
documents but will just quickly identify the presence of (or lack thereof)
procedures. Through this, the inspector will know enough to figure out if the
factory is taking training and QC processes seriously.
Ex. of Best output - Some factories are continuously gunning for their competition. They are investing in new methods and strategically try to be at the forefront among their competitors. For instance, it’s a good thing if the factory has a dashboard to share production details, rights, and quality expectations with its employees.
Ex. of Alarming output - Some factories stopped investing 10 years ago, and just keep running with the same kind of orders/products since their inception. Some of these same factories may only have one (or no) person doing QC and may try to simply finish production as quickly as possible, without an eye for quality.
2 -
Machinery
A significant
proportion of quality issues come from bad machinery calibration. It’s easy to
explain but not easy to prevent. The problem is that even if improper
calibration is obvious, line workers may not have a good idea of how to fix it,
or that they should report it. A company like AQF can provide an overview on
machinery calibration and check how the factory makes sure the tools and
machinery are constantly operational and well adjusted.
This happens by
checking maintenance records, spot check record and test records on your order.
Ex. of Best output - On certain production site, you can track down any single task done on your order over the last weeks. Date of operation, the name of the operator, what has been done, like a diary, recording the daily maintenance tasks done.
Ex. of Alarming output - Sometimes, it happens that you find broken machinery parts, spare parts just under the feet of the workers. It’s obviously not a safe idea to take off parts from an old machine to replace those on the currently used one.
3 - Production
line
Organization and
Machinery should give you a great picture about what to expect from the
production line management. After focusing on these two first points, the
inspector takes part in the production line.
As a number of
factories deal with a lot of small and medium POs, the production manager isn’t
always as trained as we may suppose. Once he has organized the line, his mind
is set on gaining flexibility in switching orders and gaining time, while
unfortunately having compromises in quality.
To help you
develop an opinion on the lines, an inspector can take the lead and focus on
the production aspect, the quality of the lines and the practical QC management.
-- AQF, for example, will provide you
with the production performance specifications (/hour, /day, /line) to ensure
the factory gives a correct output number. Plus, AQF can add great value to the way the
flows are managed; how the factory re-worked its failed goods at the QC step,
and the way the QC are dispatched throughout the lines, the rate of first pass QC and the storage condition of semi-finished and
final products.
-- At the start
of the production day, you can be sure that everything that can go wrong will
go wrong. That’s why, once in a factory, it’s significant to have a look
at the QC signs. Are they clear? Can
every single worker understand the organization? And so on. To illustrate, once
coming to front of a line, a good reflex is to first have a look if there is a
green QC pass bucket and another big enough red QC failed bucket.
Ex of Best output - Colourful and meaningful signs, markings on the ground, stickers, updated billboards… A great thing is to have someone responsible for re-organizing, cleaning up the line at each break (roughly every 5hours). This person is typically a line worker and they take turns daily.
Ex of Alarming output - When producing 40 000 items, products are piling up, and there is no way to know if such a product is defective or not. Moreover, in some case, illegal migrant workers are working overnight in the factory and the defective products are bound to mix with the passing ones.
4 - Your order: Inspection
While performing
a Production Monitoring service, your goods are inspected through AQF’s usual ISO method. A PM is not
the best path to get a full inspection of your product (compared to a PSI).
Nevertheless, even if the sampling size shrinks, you will have a good idea of
the quality of your goods.
Working specific
factories with welled QC plans implemented means your
quality is bound to increase gradually over time. Thus, being vigilant to
ensure continuation of these plans is a necessary step to take – through
a personal visit or through a trusted 3rd party.
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