Ways to Reduce Product Defects in Manufacturing

No one wants to see a product or a company done in by a defect. This is especially true if the defect
could have been prevented during the manufacturing phase. As class action suits and laws against
product defects become more aggressive, plants should take a few measures to reduce the number of
defects and their affects on the consumer.

Preventive Maintenance

Keeping the machines going that produce the units is just as important. A machine that is obsolete,
dirty or otherwise in need of care is one that cannot function properly. Sure, it may be churning out
products at or close to the average production speed. However, the units produced are more likely to
be compromised because the machine is not up to par. Loose bolts, sharp and uneven edges as well
as improperly mixed chemical ingredients are examples. With proper preventive maintenance, these
problems can be spotted and fixed before the public is affected.

Inspection Advances

There are many options available for looking into the product and testing for safety. Today’s automated
plant can evaluate several pieces at once. Ultrasonic technology, particle testing and even vibration
and resistance testing are inspection processes that many product undergo to ensure the defects
are eliminated. Inspection technology is constantly advancing in order to make this part of the
manufacturing process as short as possible.

Engineering and Production Communication

Sometimes, the problem is in the design. This is where the engineers in development should be in
constant contact with the production floor. When design flaws are suspected or or found, the engineers
can catch the problem and retool it before the exposed problem hits retailers and the consumers.
Product returns are another area where design engineers can find and fix defects on future models.
When the refurbishing department catches a pattern of defects, then it is time to consider that the defect
is in the design.
Avoiding defects in products also includes using quality materials and ingredients and having skilled
workers throughout the production process. It also includes having a plan in place to deal with defects
as they are found. Being prepared will mitigate the damage quickly, avoiding possible law suits and
consumer injuries.

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