5.7 Defects

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9 hours 3 minutes
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Hi, guys. Welcome to quick hits defects. I'm Catherine Nick Iver, and today we're going to learn the ability to identify the waste of defects.
Now, remember, downtime, defects, overproduction, waiting, non utilized talent, transportation, inventory motion and extra processing. You're gonna have this memorized by the end of this course. Um, when we're thinking about it, try to keep in mind that these air not ranked in any order.
We just organize them. So we have a cool acronym.
All right, So what is the defect defect? It's simply something that wasn't done correctly. The first time when we go into more specificity about it, it's something that doesn't meet the minimum standards. So if you think about your requirements from your sigh pock tool from
early on, when we were talking about what is a process,
your requirements are your minimum standards. So going back to the pizza joint, one of my requirements is that the pizza arrives hot. If I got the pizza and it wasn't hot, it was a defect. It
has to be fixed. It's something that you can't necessarily let slide. So when we talk about defects for a 1,000,000 opportunities, and we talked a little bit about yield rate, and we said that there were some things that could slide in some things that couldn't a defect is something that's going to go into your DPM. Oh, calculation
has to be fixed, which means this cost time and resource is it changes our bottom line
from the materials and a capacity costs. And when we start talking about the benefits of lean six sigma, we start talking about whether or not we are heard, savings or soft savings or when we say soft savings, what we're talking about his capacity. Can I do as much or more work in the same amount of man hours?
We talk about hard savings. We're gonna be talking about things like materials. So if we were able to decrease your defect rate,
we would decrease your materials cost.
All right. So
defects are pretty straightforward stuff. What causes them so defects can be caused by poor processes, which is why you guys were learning how to do process, improvement, lack of standards or standardization. So both that level one in that organisation of maturity model where I do the same work the same way
and standard work where I'm holding myself accountable to a higher standard.
It can also be caused by misunderstanding customer needs. So if you don't know, something's a requirement when you deliver it and it doesn't meet expectations, it's a defect in the mind of the customer. But it may not have been something that you could have accounted for because you didn't have a very solid voice of the customer. Or maybe the customer needs have changed.
Defects can be resolved. The most common solutions for defects are the creation of standard work plans, so they're a little bit different than procedures. But it's how we do our work, and
you can see them in S O. P. As you can see them in job job aides, you can see them in the actual standard work
work that's being done if you want to calculate it, um,
full understanding of work requirements, including customer expectations. This is really important to remember, including customer expectations, because frequently as an organization, the company has requirements. You're gonna make this widget at this price point. But that doesn't necessarily mean that it always meets what,
um, your customers are expecting,
and then the last one is simple tools. So such as job aids checklists. Um, you know, one of one of the things that I
love and it showed up in kind of an unusual places. There's this book called The Checklist Manifesto, and it was written by a physician four surgeons taking the idea of a pre flight checklist and applying it to an O. R surgical suite to decrease the number of defects. So you
you when you fly somewhere, your pilot does a preflight checklist where they go through and they checked the engines and check the instruments and is everybody on in? The doors were shut, and these are two things.
All of these could be defects if they weren't done correctly. Surgery, medical mistakes have a very far reaching implication. So this position decided that he should campaign for all, Oh, ours to have
checklists and pre surgical prep. And that's to increase that standardization. And that way we make sure that we're not missing a crucial step so that back to standard work as well
These This was super fascinating for me when it happened, and I think that you see, it's becoming more and more prevalent throughout multiple industries.
Um, when we talk about defects, remember, this is anything that wasn't done correctly or to specifications the first time. It's also can be thought of his really work if you have to go back and do it again. It was a defect.
Generally, the root of defects is communication. So it's either expectations setting with your customer or for some reason, somebody wasn't 100% clear with their role.
Those sorts of things, it does impact both the bottom line and organizational capacity on. And like I said, rework is can be a very focal topic, especially when you're starting to talk about manufacturing and scrap rates.
All right, guys,
that's defects are next. Waste we're going to look into is over production. Thanks, guys.
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