Rework is often a major unplanned expense.  What does it take to get this under control?  It must not be QC vs Production.  The starting point is recognition that you can't inspect quality into the product.  The "QC System" must be a seamless part of the way you do business, and far more than the mere duties of the QC department.  We've been there. We can help.

• Total Quality Management (TQM)    We believe that "quality is free."  A focus on quality sharply reduces rework costs, improves productivity, and builds your reputation in the eyes of your customers because your jobs go well.  click here
• Lean Manufacturing  Initiatives in Lean typically reduce noncornfoirmances and rework.  click here
• Business Strategy  Where does quality fit in your business strategy?  Balanced Scorecard can put this in focus.  click here
• Rework Reduction  A QA program should expressly address rework and rework reduction.
• Documented Processes    Quality is built on documented production processes and clear shop drawings that include finishing and other job specific requirements.  Most plant nonconformances are the result of shortcuts in the process or drawings that are unclear.
• Reporting    With modern computer systems, good reports showing trends and results are easily produced.  This is basic management, set goal and track against them.  We can help.
• Statistical Process Control    These techniques are little used but much needed in our industry.  We need only to put modern computer systems to work.  Statistical results can be used to evaluate process capabilities, evaluate vendors, or set acceptance ranges and other production process variables.
• Work Groups    The key to quality is what's happening in the work group.  Are they engaged in the process?  Are they trained?  Employee interest and involvement is essential to productivity and quality, and achievable.  We can help.
• QA/QC Manuals    The PCI now requires a unique QC manual, in a new format, for each plant .  The auditor performs his audit from the new manual, resulting in unnecessary deductions because of shortcomings in the manual.  We can help.
• Other programs    There is a place for ISO 9000 and Six-Sigma programs.  We have successfully adapted elements of these programs to PCI certified plants.  Ask about this.

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