Five tips to minimize defects in production

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The production volumes of large companies in the food industry are estimated at tens of thousands of tons of products. Manufacturers test all incoming raw materials, semi-finished products and finished goods. That is, companies conduct a huge number of analyses, as a result of which, among other things, they identify defective products.

Standards for the amount of defects at food enterprises vary depending on the nature of the products and internal quality requirements. For some companies, the acceptable value is hundredths of a percent. For other manufacturers who produce complex products and adhere to an uncompromising approach to quality issues, the kuwait whatsapp phone number acceptable level of defects can fluctuate within 2-3%.

Thorough testing of products allows to reduce the percentage of defective goods and optimize production processes. Mikhail Degtyarev, Quality Director of Mareven Food Central, spoke about how to minimize the amount of defective goods in any food production.

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Problem : Lack of communication between employees.
Advice : Create a unified quality management team.
First, quality management must be developed. This means that production processes must be initially built in such a way that problems are not identified at the quality control stage. In addition, it is necessary to regularly conduct “error correction” in order to take into account the reasons for which defects occur and to develop strategies in advance to eliminate them in the future.

Secondly, when quality management is carried out by disparate business units, this significantly reduces the efficiency of work. In this regard, it is important that the company has a separate directorate to perform tasks related, among other things, to minimizing defects in production.

Another obstacle to reducing the amount of defects is the lack of competence of the staff. In this regard, it is important to organize training for employees.

An effective way to fill the gaps in knowledge about the production cycle among personnel is to create a corporate university with multidisciplinary educational programs. Regular training on quality issues gives colleagues not only specific knowledge on how to do their job correctly, but also an understanding of why product quality and safety are really important. This awareness increases employee motivation at work.

Another useful method for reducing the volume of defects can be the formation of a special committee, where any employee can propose an initiative to optimize production processes. To inspire colleagues, they should be awarded bonuses for initiatives accepted for development. Motivated personnel who understand the principles of the enterprise are able to promptly identify problems and propose suitable solutions.

It is also important to develop mentoring programs among line employees of the factory so that more experienced colleagues can share practical skills on working on production lines with newcomers. This increases the overall level of preparedness of new employees for work at the enterprise and reduces the likelihood that defects will occur in production due to the fault of one of the team members.

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Problem : Insufficient quality of raw materials.