Quality Control System and Production Issue Management
The Challenge
Lack of issue management system and quality control in production
The company lacked an integrated system for registering production defects, inter-operational quality control, and issue management. All data was maintained in scattered Excel spreadsheets, making it impossible to effectively track problems and analyze quality indicators.
Key challenges:
- No system for registering production issues and defects
- Data scattered across Excel spreadsheets with no analytical capability
- No tracking of repair statuses or assignment of responsible parties
- Inability to monitor issue resolution times
- No inter-operational quality control checklist
- Difficulties in communication between crews and quality control
- No LT (Lead Time) indicators or production crew efficiency metrics
The Solution Process
Comprehensive quality control system with offline mode and AI
Implementation of an advanced application to manage the entire quality control process — from reporting defects with photos, through crew assignment and inter-operational inspection, to AI-powered indicator analysis. The system operates in offline mode and supports email communication.
Process analysis and mapping
Detailed analysis of the quality control process, identification of control points, development of SIPOC and issue flow diagrams across individual production stages
3 weeksSystem architecture design
Designing the data structure: orders database, issues, crews, control checklist. Preparing a legend of labels and problem categorization.
4 weeksIssue reporting implementation
Creating an issue reporting system with the ability to add photos, descriptions, and categorization, with automatic assignment to responsible crews
3 weeksChecklist and inter-operational control
Development of an inter-operational quality control checklist with the ability to generate PDF reports and track completion progress
3 weeksOffline mode and notifications
Implementation of offline mode for work on the production floor, automatic email notifications for crews, and integration with internal communication
4 weeksIndicators and AI analysis
Deployment of an indicators dashboard (LT, crew performance, problem category analysis) and an AI module for automated analysis and recommendations
3 weeksActions Taken
Defect reporting system
Mobile application for reporting production issues with the ability to add photos, descriptions, and categorization, with automatic assignment to crews
Inter-operational quality control checklist
Digital checklist for quality control at individual production stages with automatic PDF report generation
Crew management system
Module for assigning issues to crews, tracking repair statuses, accepting solutions by crew leaders, and quality control
Offline mode and communication
Ability to work offline on the production floor with automatic synchronization, and an email notification system for all stakeholders
Indicators dashboard and AI analysis
Comprehensive dashboard with LT indicators, crew performance metrics, problem category analysis, and an AI module for automated analysis and action recommendations
Results Achieved
Key metrics
Response time to issues
Problem detection rate
Repair time
Customer complaints
Business benefits
- Dramatic reduction of response time to issues from 4 hours to 15 minutes
- 65% increase in early-stage problem detection
- Transparent system for assigning and tracking issue statuses
- Digital inter-operational quality control checklist with PDF reports
- Ability to work in offline mode on the production floor
- Automated email communication with crews and managers
- Real-time LT indicators and crew performance dashboard
- AI analysis identifying root causes of quality problems
- 55% reduction in customer complaints
- Elimination of manual Excel spreadsheet entry
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