The countless, unseen details are often the only difference between Mediocre and Magnificent.

Cost of Quality Basics (CoQ)

Cost of Quality Basics (CoQ)
Quality, like finance, has various “buckets” or categories for the costs associated with the good and bad products that are created. Most often we hear about the Cost of Poor Quality, but the cost of poor quality only reflects a portion of the total quality costs. The figure below shows the 4 major categories for Quality Costs and [...]

Selling a Quality Culture

Selling a Quality Culture
A common challenge for quality professionals is that we have to go up against hey culture where operations rules the day to day activities. How do we change operational culture with a get it done attitude to respect a quality management system approach to work? Our goal as quality professionals is not to delay or hinder production but it does [...]

Pneumatic Testing Material Failure: N...

pnuematic-testing-failure-results
Well, as mentioned before, the importance of raw material quality can not be under estimated. When it comes to safety and catatrophic failures it is very common to drill down the root cause to the raw material. The following photos show how catatrophic a raw material failure can be. They were performing pneumatic pressure testing where the pi [...]

External Failure Costs

External Failure Costs
External Failure costs represent a category in the total cost of quality where the quality costs are related to defects found after delivery of the product to the customer. External failure costs are generally the highest of the 4 cost of quality categories since the full value of work and processes had to be performed to get the product to t [...]

Internal Failure Costs

Internal Failure Costs
Internal failure costs are costs that are incurred as a result of identifying defective products before they are shipped to customers.  The labor, material, and (usually) overhead that created the defective product. The areas / nonmenclature are numerous and include; scrap, spoilage, defectives, etc. The cost to correct the defective material [...]

Quality Corrosion Prevention: Zinc Ph...

Quality Corrosion Prevention: Zinc Phosphate
An important part of manufacturing quality metal products is in their longevity. Preventing corrosion can mean the difference between the having to replace metal products prematurely. There are many coating and methods that help prevent corrosion of metal; one such method is to coat the metal with zinc phosphate. Zinc phosphate is an inorgani [...]

Appraisal Costs

Appraisal Costs
Appraisal costs constitute all costs that go testing and inspection of products. The detection of defective parts and products should be caught as early as possible in the manufacturing process.  Appraisal costs are sometimes called inspection costs and are incurred to identify defective products before the products are shipped to customers. [...]

Raw Material Quality Costs

Raw Material Quality Costs
Raw material critical to manufacturing of any product. The final product is a direct result of the quality of the raw material and the potential cost of poor quality can be drastically reduced by ensuring high quality in raw materials. In the business of metal fabrication and assembly the quality of the metal has an enormous impact on the ove [...]

Prevention Costs

Prevention Costs
Prevention Costs are any costs that are incurred in an effort to minimize appraisal and failure costs. This category is where most quality professionals want to live. They say an ounce of prevention is worth a pound of cure and they is what this category is all about. This includes the activities that contribute to creation of the overall qua [...]

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