The High Cost of Manufacturing Errors
High costs of rework and scrap plague many manufacturing organizations across all industries and product lines. And the list of root causes—and, quite commonly, excuses and finger pointing—can be bewildering.
Most commonly, manufacturing blunders that result in rework, tool damage, and scrap are the outcome of poor design for assembly and manufacturing.
But quite often, manufacturing setbacks are caused by human errors, omissions, and plain misunderstandings in the process of transitioning a new product from design to manufacturing.
Other organizational ills, such as poor maintenance practices of manufacturing assets, unmotivated employees, and poor quality management, can add to the problem.
No matter the root cause, the impact of rework and scrap can be overwhelming, especially when a problem is discovered only when the organization is already in full volume production. About half of the causes for rework are discovered during ramp-up time, resulting in design or process changes that cascade to several design or manufacturing activities, and impact work in progress, inventory and supplier contacts, and are highly disruptive and resource intensive. Read More