1. Analysis background introduction
This case comes from a large manufacturing
enterprise, which mainly produces mechanical parts and electronic products,
involving many industries such as automobiles, aerospace and consumer
electronics. The company has multiple automated production lines and is
committed to providing customers around the world with high-quality and
reliable products. In recent years, with the expansion of production scale,
enterprises have also faced challenges such as complex production processes and
diversified customer needs.With the improvement of production scale and
business complexity, enterprises have quality fluctuations in the production
process, affecting the overall production efficiency and customer satisfaction.
Enterprise management hopes to identify key issues in the production process
through in-depth quality data analysis, reduce quality costs, and improve
product qualification rate and customer satisfaction.
2. Statement of key issues
1)
There are fluctuations in the internal quality indicators of the enterprise
(such as Scrap Rate, Pro NC Rate, Warranty Rate, etc.). How to identify the key
factors that lead to quality problems in the production process through data
analysis?
2) The failure rate in the production
process is relatively high, rework and scrappingThe problem is more prominent.
How to find the most problematic links and optimize them by analyzing the
unqualified data in the production process?
3) There are differences in quality
performance between different production lines and different shifts. How to
identify potential problems and improve the consistency and efficiency of the
production line?
3. Analyze the plan
For the above key issues, select key data
indicators.
|
Serial
number
|
Name
of the indicator
|
Paraphrase
|
Analysis
angle
|
|
1
|
FTT.
|
FTT=(the
number of products passed without defects/the number of total production
products)×One
hundred percent
|
FTT
(First Time Through) is a quality management indicator in the manufacturing
industry, which is often translated into Chinese as a one-time pass rate. FTT
mainly measures whether a product can pass all processes at once in the
production process without rework or repair. It is an important indicator for
evaluating the quality and efficiency of the production process.
|
|
2
|
COQ
|
COQ
= prevention cost + identification cost + internal loss cost + external loss
cost
|
COQ
(Cost of Quality), or quality cost, is an indicator used in the manufacturing
industry to measure costs related to product quality.It includes all costs
incurred to ensure product quality and failure to meet quality requirements.
COQ helps enterprises understand the impact of quality problems on the
overall cost, so as to optimize resource allocation, improve production
efficiency and product quality.
|
|
3
|
LAR-FG
|
LAR_FG=(QUANTITY
OF QUALIFIED FINISHED PRODUCTS THAT PASSED THE FINAL ACCEPTANCE/QUANTITY OF
TOTAL PRODUCTION OF FINISHED PRODUCTS)×One hundred percent
|
LAR-FG
(Line Acceptance Rate - Finished Goods), that is, the acceptance rate of
finished products, is an indicator used in the manufacturing industry to
measure the final acceptance rate of finished products through the production
line.It reflects whether the final output finished products on the production
line can meet the company's internal quality standards and pass the final
acceptance before they are delivered to the customer.
|
|
4
|
Warranty
|
Warranty
Rate (Quantity) = (Number of products with problems during the warranty
period/total number of products delivered)×100%
|
Warranty
(quality assurance cost or quality assurance rate) is an indicator used to
measure the quality problems and related costs of a product during the
warranty period. This indicator is mainly used to evaluate the cost or
proportion related to after-sales service such as repair, replacement and
recall within a period of time after the product is delivered to the customer
(usually within the warranty period).
|
|
5
|
Scrap
rate
|
Scrap
Rate=(Quantity of Scrap Products/Number of Total Production Products)×One hundred percent
|
Scrap
Rate is an indicator used in the manufacturing industry to measure the
proportion of products scrapped due to quality problems in the production
process. The scrap rate can reflect the degree of waste in production and
help enterprises evaluate the level of production efficiency and quality
control. Reducing the scrap rate is of great significance to reduce costs,
improve profit margin and the overall efficiency of the production line.
|
|
6
|
Pro
NC Rate
|
Pro
NC Rate=(number of unqualified processes/total number of processes)×One hundred percent
|
Pro
NC Rate (Process Non-Conformance Rate), or process non-conformance rate, is
an indicator used in the manufacturing industry to measure the proportion of
non-conformity or deviation from the prescribed standards in the production
process. This indicator reflects quality problems in the production process
or process, and helps enterprises identify and control potential quality
risks in order to take timely improvement measures.
|
Description: The indicators selected in
this case are common indicators in analysis.In the analysis work, priority
should be given to selecting the indicators that have the greatest impact on
the business to ensure that the purpose of the analysis is consistent with the
business objectives and key performance.
3.2 Power BI Visualization Scheme
Note: The DEMO page data is simulated data,
which is for reference only to the analysis angle and Power BI function
display, and does not involve any actual business data.
4. Analysis and interpretation
The importance of FTT:
Reduce production waste: high one-time pass
rate can avoid rework, repair and scrapping, and improve production efficiency.
Cost reduction: Less rework and repair
means lower material, labor and time costs.
Improve customer satisfaction: Higher
product quality means fewer defective products entering the market, increasing
customers' trust in products.
The importance of COQ:
Improve quality awareness: By understanding
the composition of quality costs, enterprises can more clearly identify the
weak links in quality management.
Optimize resource allocation: Reasonable
quality cost allocation can help enterprises invest more resources in the
prevention and identification stages to reduce internal and external losses.
Reduce the total cost: Although the cost of
prevention and identification will increase, by reducing the cost of internal
and external loss, the overall quality cost tends to decrease, improving the
profitability of the enterprise.
The importance of LAR-FG:
Evaluate the quality control of the
production line: LAR-FG can reflect the overall quality control level of the
production line. If the acceptance rate of the finished product is high, it
means that there are no more defects or problems in the production process.
Reduce rework and waste: By monitoring
LAR-FG indicators, enterprises can identify and reduce quality problems on
production lines, so as to reduce rework, waste and other waste.
Improve customer satisfaction: Ensuring a
high acceptance rate of finished products can effectively reduce the risk of
unqualified products and avoid potential customer complaints, returns and
after-sales problems.
The importance of Warranty:
Evaluate product quality and reliability:
WarrantyIndicators can help enterprises understand the frequency and severity
of problems in actual use of products, so as to evaluate the quality and
reliability of products.
Reduce after-sales service costs: Analyzing
common problems during the warranty period can help enterprises identify the
weak links in the product design and manufacturing process, so as to make
targeted improvements and reduce future warranty costs.
Improve customer satisfaction: Reducing
quality problems during the warranty period can not only reduce after-sales
costs, but also improve customers' satisfaction with product quality and brand
loyalty.
The importance of Scrap Rate:
Measure the quality control of the
production line: The scrap rate directly reflects the proportion of unqualified
products in the production process.High scrap rate possibility tableObviously,
there is a problem with quality control, and the production process, material
management or equipment maintenance need to be improved.
Reduce production costs: Scrapped products
mean a waste of raw materials, labor, time and machine resources, so reducing
the scrap rate can effectively reduce production costs and improve production
efficiency and profit margins.
Improve resource utilization: By analyzing
the reasons for scrapping, enterprises can identify which links cause waste, so
as to take measures to optimize the process and improve resource utilization.
The importance of Pro NC Rate:
Monitor the stability of the production
process: By tracking Pro NC Rate, enterprises canFind unstable factors in the
production process, such as fluctuations of equipment, process parameters or
raw materials, so as to optimize the operating efficiency of the production
line.
Prevent product defects: Process failure is
usually an early sign of quality problems in the final product. By timely
detection and correction of non-conformity in the process, the defects of
finished products can be effectively reduced and subsequent rework, scrapping
and other losses can be avoided.
Support continuous improvement: According
to the changing trend of Pro NC Rate, enterprises can conduct data analysis,
identify the most frequently problematic processes, and implement continuous
improvement plans to reduce the frequency of non-conformity.
5. Application effect
1. Improve production efficiency and reduce
waste through analysisScrap Rate, Pro NC Rate and other key quality indicators,
enterprises can find and optimize the production links that are most likely to
be unqualified or scrapped. For example, the improvement of automated detection
and process control not only reduces the waste of raw materials and labor, but
also significantly improves production efficiency.
2. Improve quality control and reduce
product defects. By monitoring and analyzing the fluctuations of quality
indicators, enterprises can quickly find quality abnormalities in the
production process and take timely measures. For example, analyzing Rework Rate
and Pro NC Rate can help enterprises prevent product defects and reduce
customer complaints.
3. Optimize the operation and staff of the
production lineIndustrial training Quality index analysis can also help
enterprises identify the differences between different production lines or
shifts. For example, analyzing the FTT and Scrap Rate of different production
lines can reveal that the quality control of some shifts is poor, and
enterprises can make up for the quality difference by strengthening the
employee training of these shifts.
4. Customer satisfaction improvement
Combined with customer complaints and quality assurance data analysis,
enterprises can identify the root causes of customer dissatisfaction and take
corresponding quality improvement measures. In response to common product
quality problems, optimize the design or process to reduce the customer
complaint rate and improve product trust.
5. Reduce quality costs and improve
profitability. Through in-depth analysis of various quality indicators,
enterprises can effectively reduce the cause ofQuality costs caused by
scrapping, rework and product recall. Combined with predictive maintenance,
enterprises can also carry out preventive maintenance before equipment failure
to reduce production losses caused by downtime.
Summary:
The
practical application of quality index analysis in manufacturing enterprises
can bring significant business improvements. Through the analysis of Scrap
Rate, Pro NC Rate, Rework Rate and other indicators, enterprises can not only
improve product quality and production efficiency, but also reduce operating
costs and increase profits.
But the success of this kind of analysis
depends on:
Accuracy and integrity of data: Timely
acquisition and updating of production and quality data is the basis of
analysis.
Full participation and continuous
improvement: From management to front-line employees, full participation is
required, and analysis needs to be transformed into practical actions to
achieve continuous improvement.
Through these measures, manufacturing
enterprises can significantly improve their quality control ability in the
fiercely competitive market, thus improving their market competitiveness and
customer satisfaction.