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25Jan

4 Ways to Strategize Manufacturing Quality and Reduce Recalls

“Work smarter, not harder” is an old adage that people in the manufacturing industry believe! Gone are those days when archaic paper-based Quality Management Systems and spreadsheets were hard to maintain and required time-consuming manual updating.

In this age of Industry 4.0, manufacturers seek an automated QMS that eliminates the need for hunting for a document in multiple locations. Businesses look for a solution that can allow them to collect and aggregate data in real time and bring every piece of information at the central platform.

Be it any sphere of industry, manufacturers across the globe are striving hard to produce the top-notch quality of finished goods that can quench the desires of their valuable customers and create an excellent reputation in the cut-throat competition.

When we talk about discrete manufacturing, Quality Control is one of the most important steps that facilitate customer-driven quality of goods, continuous improvement, quick response, leadership, and commitment. It is the process responsible for maintaining high standards in manufacturing unit by seamlessly testing and inspecting the sample of the output.

Let’s have a look at the 4 simple ways to strategize manufacturing quality and reduce recalls-

1. Track Quality Levels in Real-time and Set Team Goals

A quality management system that is integrated with a powerful and full-fledged ERP platform allows employees to work swiftly while identifying, monitoring and resolving QC issues like a cakewalk.

Real-time tracking provides manufacturers and QC inspectors with the data, insights, and information they need to stay in compliance with the standards. Tracing and tracking quality levels improve employee efficiency, adherence to the quality parameters, forecast accuracy, enhances the quality of product and ensures proper utilization of resources.

As per the research done by Dyer & Nobeoka in 2000 for Toyota Production System, supplier-level quality tracked and traced data is valued more than money because it fuels new sales and higher profits. Hence, manufacturers should focus on the product quality and its improvisation to ensure lesser product recalls or negative feedbacks from customers.

In fact, in the league of the US manufacturers, it has been found that the product quality followed by high service levels are the key factors that drive growth. Among these two, product quality was considered a leading measure of success by approx 92% respondents.

#Setting Team Goals

A team comes together as an effective unit that strives to achieve the challenging tasks. Whether it is about the inbound inspection, workflows on the shop floor or supplier quality management, every team should be assigned day-to-day tasks. This shall ensure the teams to contribute constructively to the productivity by meeting and exceeding customer satisfaction.

At every step, the inspection should be done with utmost dedication and quality criteria defined by customers should be followed strictly by the teams. When employees are given a handheld device and browser accessibility along with a web application for quality operations, they can by and large come up with greater productivity and efficiency. It becomes easy for them to view and update documents, add quality orders and results.

2. Maintain High Standards for Reporting and Analytics

While managing multiple responsibilities, QC professionals find it difficult to bring entire data in one place, manage employees and attain the daily tasks effectively. Fortunately, technology is a boon that drives productivity- it has empowered operators and QC managers to generate comprehensive reports, track and manage root causes, create assessments, improve traceability.

Considering the pace at which industries are evolving, it is mandatory that Quality Control teams stay armed with automated tools for overcoming the challenges. A web-based QMS solution is specifically designed to help QC inspectors analyze the data while being on the move so as to promote strategic decision making that can greatly affect the overall efficiency of the department.

#Enhanced decision making

If the quality management software is integrated with ERP system, every information that is entered by the QC inspector will be visible to the Production team, Planning department, Sales and Marketing, Finance and Warehouse Employees. Web-enabled QMS provides worldwide access to everyone and this fosters real-time visibility and data tracking.

It aligns disparate data quality activities, addresses challenges, ensures and maintains high-quality standards so that organization can outperform the competition.

3. Mobility: Anytime, Anywhere Access

Mobility is an imperative factor that offers the functionality of any time, anywhere access. To make sure that your teams accomplish the given QC tasks accurately, it is necessary for them to have a device-centric web platform. It will undoubtedly facilitate real-time tracking and visibility of goods and other resources. Employees can access, record and update the documents while traveling, sitting in the cafeteria or just after an important meeting.

The sooner quality of goods get approved, the quicker other departments will start processing their tasks. If an employee travels to another nation or city for a meeting, he can enter his observations/input on a browser-based software, it’ll encourage other departments to move forward and make a timely decision.

For the employees who prefer flexible work hours, on-site traveling or remote working, the web-based QC system is the key aspect that allows them to work dedicatedly, irrespective of the time and distance.

OptiProERP proudly offers e-TDC (Electronic Test Data Capture) that is a nimble web application designed for managing and controlling Quality Control operations on handheld devices and desktops. eTDC allows the users to –

⦁    Extract QC documents from SAP Business One modules

⦁    Enter the data captured during QC process

⦁    Save the details and post status

⦁    Export and import QC result files in excel format

⦁    Search, sort and select QC documents in multiple ways

4. Paperless Environment that Supports Automation

With a web application, quality management process becomes easier as it promotes the electronic generation of reports, time-saving, real-time data sharing with just a few mouse clicks, easy accessibility and what not?

If you are one of the manufacturers who want to streamline every QC operation (procurement, production, shipping, ad-hoc), eTDC by OptiProERP is the ultimate solution! It allows you to generate Quality Control orders, facilitates compliance, raises Non-Conformance and MRB (Material Review Board), improves timely decision making and synchronizes well with the ERP platform.

eTDC offers a great user experience- it has easy navigation, is simple to use and provides ways to automate tasks and processes. Users can filter column values with given options, edit and view the quality records, change the listing order and perform many functions on a handheld device.

eTDC is a web-based QMS and facilitates-

– Automated documentation

– Real-time visibility and tracking of data

– Anytime, anywhere access

– Optimization of resources and cost saving

– Enhanced decision making

– Improved reporting and analytics

If you are a manufacturer who would like to know more about the importance of web-enabled QMS solution, feel free to email us at optiproinfo@optiproerp.com. We are here to help you!

Download eBook on selecting ERP Software for Manufacturing Industry if you wish to learn more about ERP solution and how it can help your manufacturing business with its functions