To address the quality issues at the production facility of the Disney vendor, quality and process improvements were recommended. The proposed process flow is shown below:
The flow is specifically designed with continuous process improvement in mind. It includes quality checks at multiple phases of the production cycle from parts acquisition and validation and sample production run checks to continuous validation during production and packaging. In addition, any failures are being investigated and recorded allowing for further improvement of process and product quality.
Using this data, a Pareto analysis can be conducted to determine the most common defects that are being seen during the production process. A sample Pareto chart is shown below:
Currently, the vendor conducts an end of process sampling as their validation and is having issues with a growing quality deterioration as stated in earlier posts. The new process and previously discussed control charts and Pareto Analysis should find and alleviate most issues.