How to reduce scrap?

Hello there,

Industry: Automotive
Major product: Brake Discs
Problem: High level of scraps

I just started my work as QM in the Automotive industry. In the manufacturing process, we have a lot of scraps (set up of CNC machine).

How to reduce scraps? What do You use to reduce them?

I know It's not possible to eliminate them...


I have an idea to eliminate problems on the production line.
To realize this I have to build the problem-solving team and arrange regular meetings. I'd like to engage the operator.
Can You recommend me best tool to eliminate the cause of problems in the fast and easy way on the production line?

What do You think about Suggestion Board and Problem Board? In Your opinion, It's a good way to improve the process?

Thank You for feedback.

Gr. Kristof

 

The good solution to above problem. Lets me know if I think in a good way:

1. Monitor Process.
1. Using Diagram Pareto -> categorize which group of product/ machine generate the highest level of failure/ scrap.
2. Analyze the most occurs failures using 5Why or other quality tools.
3. Define countermeasure for causes.
4. Implement countermeasure for causes.
5. Verification of result-> once again monitor a process.

Thank You for feedback.

Gr. Kristof

 

Maybe a Kaizen event? Start with google.