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Sometimes there is nothing you can do about waste. Hopefully, in those cases, the waste is minimal and there is a small impact on the rest of the operation. Also, some wastes are much too big to ignore and some wastes are so bad, that they are considered deadly wastes. They are the types of waste that drain money and time away from the company and can even cause the company to fail.One of these wastes is defects. Defects affect every aspect of the process and the business. You may just think that if there's a defect, you merely throw it away and make another one. If it was that straightforward and it didn't go any farther than that, this may seem like a reasonable solution. However , how do you prevent that defect from occurring again? Was it brought on by an operation that was performed in house or did it arrive that way?If it did arrive this way, that is to say defective, then how far along in the process did it get before it was discovered? Why wasn't it identified instantly and sent back to the supplier? Without a good quality control department and process in place, you will be at the mercy of suppliers and have to hope that the assembler or whoever touches that product realizes and discovers the mistake before it gets into the final product. If the defect was due to something in house, then what caused it?Was it an operator error or a machine error, what caused the mistake and how many mistakes were made? Mistakes will occur, that is just part of life, however limiting the mistakes is where time and money will ultimately be saved. And think about what happens when the defect makes it past all of the safeguards and checks that you have in place. What happens when it makes it all the way into a customer's hands?Will that customer give you the benefit of the doubt and be understanding about the one time mistake that just happened to affect their order or will they lose their trust in your ability to provide a quality product and find somebody else to fill their needs? Hopefully your relationship with the customer is strong enough to make it through a rough patch like this, but often, in this age of anonymous ordering online and over the phone, will you ever have the chance to build that relationship?
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