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All about reducing product defects

The effectiveness of the manufacturing process is found in lowering the rate of product defects. When a manufacturer can reach low levels of product defects they are able to increase the profitability and productivity of their production process. However, it is important to understand that the manufacturer will have to take a proactive stand toward reducing product defects. This is not something that is inherent in the production process.

Most manufacturers turn to Six Sigma or other process improvement strategies to help reduce or eliminate product defects. The bottom line is that if you want to increase your productivity and save money you must focus on reducing product defects. You should also consider involving your employees. Your employees will have higher morale when you involve in them in the process of reducing product defects. This is because employee involvement can give you a bird's eye view of what is happening with your products. Your employees will be excited to help reduce product defects, improve efficiency and help to secure their jobs.

The first step to reducing product defects is to clearly identify what you need to change in order to reduce the number of defects. Start by asking your employees and then look at the production process from every conceivable angle. Your employees may be able to shed some light on the production process in way that you may not have even thought of. Make sure that you are considering cost effectiveness while you go through this process. If it doesn't make sense "dollar and cents wise" then it won't help you in the long run. If you are still struggling on how to identify ways to reduce product defects then you may want to consider hiring some consultants. A Six Sigma consultant may be able to shed new light on the problem and best of all, do it in a financially positive way. An outside consultant can not only help you identify how to reduce product defects but also help you put a new production process into place, as well.

After you have identified what you need to change in order to reduce product defects you will need to put together a plan on how to change the production process. Many manufacturers choose to use a group approach. The group will meet and brainstorm ideas that could be used. It is important before making a final decision that you consider all of the possibilities. In addition, it is crucial to look at how the machines are running since this can often be a major cause of product defects. When you have all of the necessary information then you can make the right decision on how to proceed to reduce product defects.

Once you have come up with a plan it is important that you don't just implement it and walk away. You should make sure that there is a process in place that is checking the new production process and making sure that product defects are really being reduced. Keep in mind that what may have seemed like the right idea may not be after the plan is implemented. You may still need to make changes in order to get the outcome that you are looking for. Keep checking with your employees in order to see if the changes you have made are the right ones. Finally, if you are seeing changes but think you should still see more consider going back and working the steps again, in order to determine where further changes should be made to reduce product defects. As a final step make sure that you are keeping written records of all production changes and the noted outcomes.

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