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Non-quality is a recurring issue in the day-to-day operations of industrial companies. Yet few manage to measure its real impact on their business and define effective corrective actions. FILAB helps you turn non-quality into a competitiveness challenge for your company.
What is non-quality?
In industry, non-quality refers to any non-conformity affecting a product, part or material that fails to meet the customer’s specifications: visual defects, incorrect dosage in a product’s composition, underestimated mechanical performance, etc.
These non-conformities generate significant costs for the company during the production process (scrap rates, additional working hours, surplus raw materials, etc.), as well as after the sale (customer returns, transport costs, temporary suspension of sales, etc.).
According to a 2017 study conducted by AFNOR among 816 French industrial companies, the costs associated with non-quality account for an average of more than 5% of revenue, making them far from negligible in a profitability strategy. Before undertaking improvement initiatives, it is necessary to identify the sources of malfunction by implementing reliable and effective indicators.
Why is it important to measure non-quality?
Measuring production non-quality is, above all, about recognizing the extent of its weaknesses. But that is easier said than done! According to the AFNOR study, 20% of the companies surveyed admitted that they did not know how to measure their non-quality costs due to a lack of indicators.
What steps should be followed?
① Define relevant indicators. Using automated IT tools, the preliminary objective is to examine the theoretical path of a part or product and associate it with various performance indicators: time, costs, labor, delivery rate, etc.
② Analyze the data collected regularly. This data will help identify the sources and causes of anomalies and define a corrective action plan: optimizing tools, reviewing suppliers’ specifications, improving workstation ergonomics, etc.
③ Set objectives for reducing costs or losses over one year.
A non-quality cost management strategy will minimize discrepancies between forecast and actual costs on a production line. As part of this approach, support from an external service provider gives you a fresh, impartial view of your processes and provides broader industrial experience.
How does FILAB support you in your strategy for managing non-quality costs?
Through site audit services, FILAB provides access to the multidisciplinary knowledge of its experts to help you optimize your processes. From receiving raw materials to putting products on the market, we identify malfunctions that affect your costs, lead times and product quality.
Depending on the results obtained, FILAB offers personalized support at several GO\/NO GO stages, such as:
Nos accompagnements personnalisés
Aide à la définition de cahiers des charges plus exigeants sur les critères de qualité
Automatisation de certains procédés
Proposition de formations pour accompagner les équipes dans de nouvelles démarches qualité
Modification des paramétrages outils pour réduire les risques de défauts
Développement de méthodes analytiques ou réalisation de kit d’analyse pour évaluer plus rapidement la qualité des matières ou produits.
Mastering your process and having a thorough understanding of your materials are essential criteria for reducing non-quality costs. With FILAB, you will have direct access to technical contacts, and your projects will be carried out in complete confidentiality.
An example of a problem solved…
With the objective of reducing costs associated with non-quality, a major company operating in the luxury sector called on the expertise of our materials department several months ago. The company was experiencing significant scrap rates that affected its delivery times, forced it to overestimate raw material inventories and required additional labor.
Through several site audits and numerous discussions with the client, FILAB studied the theoretical path of the various parts that made up the product in order to identify the causes of the anomalies. Using the defect database made it possible to characterize the production process defects responsible for product failures and quickly implement corrective actions:
Nos actions
Définition d’un cahier des charges de matières premières plus exigeant, basé sur les critères de qualité
Modification du paramétrage de certaines machines (température, coupe…) pour réduire les risques de défaillances
Formation du personnel à ces nouveaux procédés
Mise en place de contrôles qualité internes à réception des matières premières
Automatisation certaines manœuvres afin de réduire les écarts de production
These actions reduced scrap rates from 10% to 2% in less than a year, thereby improving production planning. The investment costs associated with FILAB’s services were also quickly recouped.
Because measuring and reducing non-quality is at the heart of our work, put your trust in us!
