3 Manufacturing Quality Metrics Everyone Should Know
It’s important to understand how objectives in manufacturing — like improved quality— can be engineered through better data. This all starts by understanding the best manufacturing quality metrics and being able to discern which levers are responsible for moving the needle on this goal.
Quality is an essential part of OEE; which gets talked about a lot. In fact, I’ve discussed this ad nauseam.
The truth is that quality is just like availability and performance. It is relative to the manufacturer.
For some, it is clearly a more meaningful factor than others. What’s more, some may even sacrifice aspects of their quality to improve things like performance and availability. But, the truth is that it is impossible to make these decisions without accurate data or a solid understanding of the metrics that matter most to manufacturing quality.
Metrics that matter to manufacturing quality
So, what are the three metrics that matter most to manufacturing quality?
Well, beyond being the most important, let’s think about which metrics might be the most helpful to understand in the context of your plant floor.
1.) Manufacturing Yield
Manufacturing yield is the percentage of something that is manufactured according to the manufacturer’s predetermined specifications in the original manufacturing process— without producing any scrap.
This is important for understanding the percentage of time that things are produced exactly how it is drawn up on the whiteboard.
2.) Customer Returns
This is essentially the metric for understanding the percentage of products that the customer returns or rejects.
This could be because the product is outside of specifications, defective, or damaged.
This connects well with yield because if you’re a manufacturer with a really high positive manufacturing yield, but an abnormally high customer return rate, there is obviously some kind of disconnect.
Truthfully, the most important factor in comparing these two metrics is ensuring that the metrics are accurate to life; meaning that you are actually seeing the real numbers.
Often, the numbers will get fudged to achieve an industry-acceptable number. However, as things are looked at retroactively, it becomes clear there is a problem.
3.) Supplier materials quality
This is really the last variable in the equation.
Supplier material quality looks at the number of goods coming from the supplier that reach the manufacturing with an acceptable measure of quality. This means that these materials can be used effectively to produce the products.
All these manufacturing metrics line up
It’s very easy to see how all of these metrics are essential to get a 3-D picture of manufacturing quality.
If your data is accurate, these metrics will paint a picture of where things may be breaking down in the chain. For example, if everything is presumably good until the customer receives the products, then the rejection rate jumps up you could begin to investigate that part of the chain.
Honestly, as we discussed above, the most important factor in all of these manufacturing metrics is understanding that the source of truth of this information is accurate.
Furthermore, it’s essential that this info is reviewed regularly or in real-time. This way, manufacturers don’t miss out on the opportunity to effect this issues before they become multi-month, systemic problems. In many cases, issues in this area will persist for years and years (and are known by those on the factory floor, but never raised to management).
What to do next?
If you’re not leveraging a manufacturing analytics application, it can be hard to understand all of these elements properly.
If you’d be interested in giving SensrTrx a closer look, you can do it here.
Otherwise, leave questions and comments below.