Although there are detailed production instructions as a reference during the production process, product quality abnormalities often occur, and it has a great impact on production efficiency and quality. The timely and effective confirmation, analysis, processing and tracing of product quality abnormalities by the first-line team leader is the key to improving the team's production efficiency, production yield and product quality. So how to handle product quality abnormalities?

 

Confirm products with quality abnormalities

There are three main steps to determine the products with quality abnormalities: first, analyze the type of defect; second, analyze the degree of defect; finally, count the number of defective products in the problem position.

 

1. Analyze the type of defect

 

For poor appearance, determine which workstation has a problem based on the specific defective part; for poor performance, disassemble the product for a comprehensive inspection to find the cause; for poor size, a comprehensive analysis of the equipment and operation is required to find out the cause of the defect.

 

2. Analyze the degree of defect of products with quality abnormalities

If the defect is minor and does not affect the performance of the product, the team leader can arrange for technically skilled personnel to repair it, and then enter the next process or put it into storage. If the repair is not good, the performance and service life of the product will be affected, and the team leader will arrange for the material personnel to apply for scrapping. If it is confirmed at the beginning that the product is seriously defective and does not belong to the repairable range at all, then you can directly apply for scrapping. If the defect has never occurred before and the team leader cannot determine the extent of the product defect, it is necessary to temporarily stop the production of the production line and immediately report to the superior leader, waiting for the leader to issue a handling opinion, so as to avoid the increase in the number of defective products.

 

3. Count the number of defective products in the problem position

 

When the defect type and degree of defect are determined, the number of defective products in the problem position must be counted. If five or more defective products appear in a row at a certain station, production must be suspended to find out the cause. If the defective products appear intermittently, you can analyze and produce at the same time.

 

Take appropriate measures according to the cause of quality abnormality

For products with abnormal quality, it is necessary to do a good job of corresponding treatment according to the actual cause. What are the general causes of quality abnormality and how to deal with it? The reasons for quality abnormalities can be analyzed and dealt with mainly from five aspects:

 

(1)Process document problems

First, confirm whether the production process documents are correct. Generally, product quality abnormalities are unlikely to be caused by process documents. It is a standard reference document. Once there is a problem, it is a very big problem. This situation usually occurs at the beginning of production or after the process is changed. In mass production, this situation rarely occurs. If there is a problem with the process document, production must be stopped, because if the process is wrong, all the products produced will have problems, and there will not be a situation where some products are qualified and some products are unqualified. After stopping production, the team leader must report to the superior immediately, either directly orally or orally and then in writing. Then wait for further instructions from the superior.

 

(2)Machine and equipment problems

 

After confirming that there is no problem with the process document, we must also confirm whether it is a defective product caused by the machine and equipment. For defective products caused by machine equipment, in addition to stopping the production of the equipment error position and notifying the maintenance personnel to repair, the machine operator should also record the maintenance time, so that the production loss caused by the equipment maintenance can be deducted from the production task of the day, so as to avoid continuing to start the machine to produce more defective products in order to complete the production task.

 

(3) Operation method problem 

Because the defective products caused by improper operation methods are also easy to ignore and make mistakes for many employees, you can ask the employees in the problem position to operate again to see where the mistake is. Is it caused by his failure to comply with the requirements of the process documents or because he violated the machine operation requirements? After knowing the error point and the cause of the error, the team leader should guide the employee to change the wrong operation method and repeat the operation on the spot until the operation is correct. If the employee cannot be taught no matter how hard he tries, or has a bad attitude, the team leader can decisively replace the personnel. There is no need to waste time.

 

4. Raw material problem

We also need to consider whether there is a problem with the raw materials. If the product quality is abnormal due to raw material problems, the team leader should hand it over to the quality department for processing.

 

5. Environmental issues

Environmental issues can also cause product abnormalities.

 

For example, workshop hygiene and temperature and humidity at the production site. If it is a workshop hygiene problem, the team leader should organize employees to clean up, clean up the hygiene of the bad positions, and wipe the equipment of the bad positions, including the inside and outside of the equipment. Clean the fixtures used to produce defective products. Sometimes small foreign objects are hidden inside the fixtures, and you can consider using a small toothbrush when cleaning.

 

Sometimes temperature and humidity problems can also cause product defects. For example, the production and storage of electronic products have temperature and humidity requirements. The humidity specification of general products is 50±20%, and the temperature specification is 23±5℃. When the temperature in the workshop is abnormal, you can turn on the air conditioner to ensure that it is within the temperature requirement range. When the humidity in the workshop is abnormal, you can turn on the humidifier or dehumidifier to adjust it so that the humidity meets the standard.

 

Trace the flow of products with abnormal quality

The flow of products with abnormal quality needs to be traced in two directions. First, for defective semi-finished products still on the production line, if the defective semi-finished products are found in this station, just distinguish the defective products at your own station. If defective products from the previous process are found in the later process, the semi-finished products from the defective station to the defective station should be distinguished, and these semi-finished products should be placed by category, marked as defective, and then put into the unqualified management area. All relevant personnel should re-test them. However, if the defective products have flowed into the finished products produced on the same day, the finished products produced on the same day should be managed separately, and the number of affected products should be counted first, and marked as defective, and then put into the defective product management area for management.

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