The Importance of Quality In Manufacturing
Simply put, without quality, there is no distinction. Premium car designers know this and so will opt to source higher-quality components to use in their vehicles, with the aim of delivering an elevated driving experience to their end customer. In this article, Claire Lloyd, quality manager at Vestatec, shares her top tips for maintaining quality throughout the manufacturing process and explains how the company’s approach to quality control enables them to surpass the notoriously stringent standards set by automotive OEMs.
There are two ways to look at quality. For the vehicle’s owner, it is about the perception of quality and durability. Does the product quality and overall experience meet my expectations as a customer? However, for manufacturers, it is equally about process quality. How do the processes followed, not only drive efficiency and effectiveness but also deliver that high-quality product that contributes to the customer perception?
As a leading supplier of premium metallic interior trim components to the automotive industry, at Vestatec we pride ourselves on the quality of our processes and the quality of the products those processes enable. We understand that OEMs and Tier 1 manufacturers expect and demand high-quality interior trim, every time. That’s why our quality inspection processes incorporate meticulous inspections, employee empowerment and a constant commitment to perfection, which collectively contribute to delivering exceptional products.
Continuous inspection integrated throughout the manufacturing process ensures the consistency of the product, and our quality process means that there are many opportunities for intervention, from receiving raw goods to final packaging.
Consistency
Continuous inspection integrated throughout the manufacturing process ensures the consistency of the product, and our quality process means that there are many opportunities for intervention, from receiving raw goods to final packaging.
Efficiency
As a business, we adhere to the Kaizen 5S principles of sort, straighten, shine, standardise and sustain. This ethos is embedded into everyone at Vestatec, from the shop floor through to senior management and regular audits ensure all employees are meeting the required standards. It ensures that each workstation is clean, clear, worker-friendly and fit for purpose.
When put into practice and embedded into the culture of the company, 5S supports manufacturing efficiency by providing the framework for a smooth, standardised workflow. On the shop floor, this efficiency is a key factor in ensuring consistency across part runs and between batches.
Effectiveness
Manual inspections are only as good as the people who undertake them; therefore, maintaining a high standard of inspections is a continuous operation. Everyone who is in contact with the product is jointly responsible for quality and needs to be confident in raising concerns. But to have a team that can do this requires investing in people.
Every member of our manufacturing team goes through rigorous quality training to help them identify any non-conforming components and we run regular refresher courses to ensure that each member of staff is up to speed with our processes.
Of course, there is technology available to do some checks. For example, a CMM machine is a great tool for measuring parts’ dimensions and comparing them against the specifications detailed in the customer CAD drawings. However, when it comes to quality control, we believe there is nothing better than a well-trained operative on the shop floor who feels empowered to make decisions on defects themselves. An additional layer of screening is provided by our dedicated quality engineers, who conduct thorough batch checks to ensure each product leaving our facility is to the highest standard.
Compliance
Compliance with industry guidelines and international standards are an integral part of our internal processes. The IATF 16949:2016 standard which Vestatec holds, incorporates the structure and requirements of the ISO 9001:2015 quality management system standard, with the addition of some automotive customer-specific requirements.
Compliance with these industry standards helps us when we ‘plan, do, check and act’ and strict adherence to these processes align with our own internal compliance, policies and procedures. The results from our most recent IATF 16949 audits are a testament to our commitment to these systems, putting us in the top 3% of automotive suppliers globally.
Empowerment
At Vestatec, we believe that our company achieves effectiveness through employee empowerment. All of our employees are empowered to halt production in the name of protecting product quality, a vital action each member of our team must be willing to take when necessary. It gives us the flexibility to adapt and contain issues as they arise.
Through employee empowerment, supported and reinforced by extensive internal training, we’re able to ensure every member of the team is vigilant in identifying non-conforming parts before they reach the customer.
Continuous Improvement
Continuous improvement is a well-worn phrase in automotive manufacturing. So, when it comes to quality management, how do you ensure it happens rather than just paying lip service to it?
A strict regime of internal audits and spot checks is a strong starting point for regularly auditing our product processes to help maintain high standards and genuinely drive continuous improvement.
In addition, we’ve implemented forums for daily meetings on quality improvement, where the quality team communicates status updates on open issues and ongoing actions. This is also an opportunity for the wider team to raise any concerns they may have.
Control
At Vestatec, we control and monitor every aspect of the supply chain, carrying out quarterly reviews, and awarding our suppliers a score based on their levels of logistics, service and quality. This data-driven approach not only helps us to select the best suppliers for our products, but also means we can quickly identify and rectify any issues if they arise.
Customer Focus
For Vestatec, success is meeting or even exceeding our customer’s expectations and those of our customers’ customers. This includes monitoring and incorporating customer feedback. In this business, minimal feedback is usually viewed as a positive sign of customer satisfaction, but it’s important to note that even with happy customers it is key that quality processes should always be continually reviewed for improvement!
Striving for perfection
At Vestatec, our ethos goes beyond setting high standards or taking pride in a high level of quality. Our perfection-oriented mindset is what drives us to continuously improve, and it is what sets us apart from our competitors.
Overall, true quality management delivers measurable benefits for customers, such as reduced product failures, increased satisfaction and enhanced brand perception. In an increasingly competitive vehicle market, integrating unwavering quality assurance with innovative styling and product differentiation is a winning combination.
For more information: www.vestatec.co.uk
