{"id":9196,"date":"2021-01-19T10:51:43","date_gmt":"2021-01-19T18:51:43","guid":{"rendered":"https:\/\/www.qad.com\/blog\/?p=9196"},"modified":"2021-02-24T15:35:37","modified_gmt":"2021-02-24T23:35:37","slug":"building-a-quality-culture-design-quality-from-the-start","status":"publish","type":"post","link":"https:\/\/www.qad.com\/blog\/2021\/01\/building-a-quality-culture-design-quality-from-the-start","title":{"rendered":"Building a Quality Culture: Design Quality from the Start"},"content":{"rendered":"<p>[vc_row][vc_column][vc_single_image image=&#8221;9198&#8243; img_size=&#8221;full&#8221;][vc_column_text]<span style=\"font-weight: 400;\">This is the first in a series of blog posts digging deeper into the seven keys to building a quality culture, which builds on Nicole Parker&#8217;s <\/span><a href=\"https:\/\/www.qad.com\/blog\/2020\/12\/7-keys-to-building-a-quality-culture\"><span style=\"font-weight: 400;\">recent introduction blog<\/span><\/a><span style=\"font-weight: 400;\">. In this article, we will discuss the first of these seven keys. <\/span><\/p>\n<h2>Design Quality from the Start<\/h2>\n<p><span style=\"font-weight: 400;\">Employees want to design the best products for their customers, so why do we still have quality issues? I argue it is a <\/span><a href=\"https:\/\/www.qad.com\/blog\/2018\/02\/quality-management-executive-support\"><span style=\"font-weight: 400;\">management enablement<\/span><\/a><span style=\"font-weight: 400;\"> issue requiring involvement of the right employees, giving them <\/span><a href=\"https:\/\/www.qad.com\/documents\/data-sheets\/enterprise-quality-management\/eqms.pdf\"><span style=\"font-weight: 400;\">proper tools<\/span><\/a><span style=\"font-weight: 400;\"> and processes and most importantly, the environment to be successful in the up-front design to eliminate and minimize quality problems. There are 4 aspects to ensure we design quality from the start.<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Designing for extreme prevention<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Leveraging knowledge from the past<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Managing the new product introduction process<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Incorporating the supply chain<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Let&#8217;s talk about each of these and discuss the tools, steps, and environment that can enable them.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Design for Extreme Prevention<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The term &#8220;extreme&#8221; is used to compel employees to take prevention to another level. It pushes them out of their historical norms of prevention and gets them to think beyond how they think today. It means we need to gather our brightest, most experienced, and most skeptical minds together as a powerhouse team to identify all the design considerations before design starts. We will discuss teams in further detail in a future blog, but \u201cwho\u201d is involved is very critical to success.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The goal is to design prevention of any <\/span><a href=\"https:\/\/www.qad.com\/blog\/2019\/09\/the-top-five-quality-management-system-failures-of-all-time\"><span style=\"font-weight: 400;\">failures<\/span><\/a><span style=\"font-weight: 400;\">. These are not just failures an end-user might experience, but failures in processing, procurement, assembly, maintainability, serviceability, sustainability, etc. Rarely does a single person understand all of these areas, much less more than a couple of them. We need those perspectives up-front.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Customer requirements and how the product will be used should be reviewed, then concerns and design considerations of all stakeholders should be documented so they can be addressed by the design team as requirements. Then, the design team can define design failures\/risks to understand the important, critical, and reasonably likely risks and to mitigate those risks within their design. Next, the design team can design the product before those designs are formally validated against all of the customer and internal stakeholder requirements and risks.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Leveraging Knowledge from the Past<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The \u201cpowerhouse\u201d team has a wealth of knowledge and experience, so their involvement can save untold future costs or quality issues. Having business systems that will help document and effectively utilize that knowledge are invaluable. The obvious benefit is to stop repeats of past problems, but less obvious benefits might include any of the following:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Efficiency<\/b><span style=\"font-weight: 400;\"> &#8211; building a library of design failures\/risks for different types of systems can be leveraged in future designs for similar products.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Retaining Intellectual Property<\/b><span style=\"font-weight: 400;\"> &#8211; the knowledge in employees\u2019 minds is not leverageable if it is not documented, should they be retiring baby boomers or younger employees not likely to stay with the same company as long.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Making Systemic Improvements<\/b><span style=\"font-weight: 400;\"> &#8211; design improvements from one part number, through library-based failure\/risks, can help facilitate the same improvements in existing and future products.<\/span><\/li>\n<\/ul>\n<h2><span style=\"font-weight: 400;\">Managing the New Product Introduction Process<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Successful launch of a product doesn\u2019t simply mean the sound design of the product, it also includes how the product is built and tested, defining the bill of material, deciding what materials\/subcomponents are made vs. purchased items to meet capacity and cost objectives. It also includes managing suppliers\u2019 quality &#8211; we will discuss this more later. Managing these aspects of new product introduction has a big impact on achieving good first part quality and sustaining that quality. Having processes and systems are crucial to enabling the team to <\/span><a href=\"https:\/\/www.qad.com\/blog\/2018\/11\/the-top-risks-of-not-having-a-quality-management-system\"><span style=\"font-weight: 400;\">manage the risks<\/span><\/a><span style=\"font-weight: 400;\"> of new product introduction. Without that efficiency that work will only be cursory or not be done at all.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Similar to the design phase we discussed, now that we know what we need to build vs. buy, process or manufacturing engineers can determine how best to manufacture the parts by determining process flow, identify the failures\/risk for each of those processes and ideally determine how they will prevent those failures. When prevention is not possible a plan to at least be able to detect the failure is necessary. It is encouraged to determine process characteristics (machine speed, torque, temperature, etc.) that will ensure and prevent a quality problem. Measuring product characteristics is almost always too late, value has already added to the bad part if the check fails.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Incorporating the Supply Chain<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The quality of the supply chain determines the quality of the product. This is why it is crucial to make the right sourcing decisions not solely based on quoted price. During the RFQ process, it is important to be able to pick the supplier based on the best quality, delivery, expertise for that item, price, lead-time, etc. or quality, either perceived or real, will suffer. Without a system to help administer the RFQ and sourcing process, it can take too much effort and sourcing will likely go to the current supplier base, providing little leverage or improvement.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">All aspects of supply chain interactions can impact quality. In the design phase, it may be important to review requirements with suppliers so there are no misinterpretations. During <\/span><a href=\"https:\/\/www.qad.com\/solutions\/integrated-supplier-management\"><span style=\"font-weight: 400;\">supplier development<\/span><\/a><span style=\"font-weight: 400;\">, incorporate the supplier into the NPI process and have them begin sending validation documentation as they develop their parts\/materials so problems can be headed off before they put your timing or overall product quality at risk. Communication and the relationships with suppliers should be no less than it is internally. We are also seeing the Amazon effect on customer expectations for delivery, so quality and supply chain professionals are going to have to learn from each other to vastly improve delivery performance.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Building a culture of prevention and design for quality will require more work up-front for at least the first couple of new products, but it will lead to the preventive culture that will dramatically reduce the cost of quality over time. The rule of 10 tells us that for every department a quality problem progresses through, it will produce a 10x increase in the cost of the quality problem. Investing in up-front quality will improve margins much more than cleaning up the problems after they are present.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Feel free to download and share our \u201c7 Keys to Building a Quality Culture\u201d infographic below.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_single_image image=&#8221;9137&#8243; img_size=&#8221;full&#8221; onclick=&#8221;custom_link&#8221; link=&#8221;https:\/\/meet.google.com\/linkredirect?authuser=0&amp;dest=https%3A%2F%2Fwww.qad.com%2Fdocuments%2Finfographics%2F7-keys-to-building-a-quality-culture.png&#8221;][\/vc_column][\/vc_row]<\/p>\n","protected":false},"excerpt":{"rendered":"<p>[vc_row][vc_column][vc_single_image image=&#8221;9198&#8243; img_size=&#8221;full&#8221;][vc_column_text]This is the first in a series of blog posts digging deeper into the seven keys to building a quality culture, which builds on Nicole Parker&#8217;s recent introduction blog. In this article, we will discuss the first of these seven keys. Design Quality from the Start Employees want to design the best products [&hellip;]<\/p>\n","protected":false},"author":101,"featured_media":9198,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[200,182],"tags":[1502,1506,1503,1505,478,113,1466,376,34,1504,1507,1508,92,118],"class_list":["post-9196","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-culture","category-featured","tag-7-keys","tag-bill-of-material","tag-management-enablement","tag-materials-management","tag-prevention","tag-quality","tag-quality-culture","tag-quality-management","tag-quality-management-system","tag-quality-problems","tag-risk-prevention","tag-supplier-development","tag-supply-chain","tag-supply-chain-management"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Building a Quality Culture: Design Quality from the Start | QAD Blog<\/title>\n<meta name=\"description\" content=\"Building a quality culture means designing quality from the start. 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