Quality-Production Silos
Quality tracked 5.2% rejection rate. Production tracked OEE and parameters. Neither team understood the direct correlation between specific parameters and defect rates.
What Became Visible
Quality-production correlation analysis revealed: pressure range 5.8-6.1 bar optimal for 0.5% defects; outside this range defects escalated to 4-6%. Temperature 22-24°C optimal; outside this range defects increased. Specific operator techniques produced 50% fewer defects.
Parameter-Driven Quality Control
Production parameters optimized for quality outcomes, not just efficiency. Operator techniques standardized to highest-quality performers.
How it worked: Correlation analysis revealed optimal parameter ranges for quality. Process control tightened around optimal ranges; operator training focused on quality-optimized techniques.
Results
from quality improvement
improvement
Quality and production are not separate systems. Quality integrated into production parameters and operator training drives systematic defect prevention.
Operational Reality
The facility had the ability to optimize parameters for quality. Quality-production integration revealed it and made optimization obvious.