Quality Control Challenges on the Floor

We’ve been facing some consistent issues with product quality on the floor, particularly during our afternoon shifts… I’ve noticed that when we get busy, corners start to get cut, and that’s unacceptable. Looking to gather insights on how others handle similar situations and maintain high standards under pressure.

‌⁠‍⁠​‍​‍‌⁠‌​​‍​‍​⁠‍‍​‍​‍‌‍‍​‌‍⁠⁠‌⁠‌‌‌⁠​⁠‌‍‌‌‌‍‍⁠‌‍‌‌‌‍‌‌‌⁠​​‌‍‍‌‌‍⁠‍‌‍‌⁠​‍​‍​‍⁠​​‍​‍‌‍‍⁠​‍​‍​⁠‍‍​‍​‍‌‍⁠‍‌‍‌‌‌⁠‌⁠‌‌⁠⁠‌⁠‌​‌‍⁠⁠‌⁠​​‌‍‍‌‌‍​⁠​‍​‍​‍⁠​​‍​‍‌‍‍‌‌‍‌​​‍​‍​⁠‍‍​‍​‍‌‍⁠‍‌‍‌‌‌⁠‌⁠​‍​‍​‍⁠​​‍​‍‌‍‌​​‍​‍​⁠‍‍​‍​‍​⁠​‍​⁠​​​⁠​‍​⁠‌‍​⁠​​​⁠‌​​⁠​​​⁠​⁠​‍​‍​‍⁠​​‍​‍‌‍‍​​‍​‍​⁠‍‍​‍​‍‌‌‌‌‌‌​⁠‌​‍​‌⁠​⁠​⁠‌‌‌⁠‌‍‌‌‌​‌‌⁠⁠‌‌​⁠​⁠​‌‌​‌‍‌‌​‍​⁠‌‌‌​​‍‌‌‌‍​⁠​⁠​‍​‍‌⁠⁠‌​​

When we hit those busy afternoons, we set up a quick huddle just before the shift. This way, we reinforce quality checks and keep everyone on the same page. It’s simple but makes a big difference in maintaining standards. Would love to know if others have tried something similar.

‌⁠‍⁠​‍​‍‌⁠‌​​‍​‍​⁠‍‍​‍​‍‌‍‍​‌‍⁠⁠‌⁠‌‌‌⁠​⁠‌‍‌‌‌‍‍⁠‌‍‌‌‌‍‌‌‌⁠​​‌‍‍‌‌‍⁠‍‌‍‌⁠​‍​‍​‍⁠​​‍​‍‌‍‍⁠​‍​‍​⁠‍‍​‍​‍‌⁠​‍‌‍‌‌‌⁠​​‌‍⁠​‌⁠‍‌​‍​‍​‍⁠​​‍​‍‌‍‍‌‌‍‌​​‍​‍​⁠‍‍​⁠​‌​⁠‍‌​⁠‌‍​⁠​⁠​⁠‌‌​⁠‍‌​‍⁠​​‍​‍‌‍‌​​‍​‍​⁠‍‍​‍​‍​⁠​‍​⁠​​​⁠​‍​⁠‌‍​⁠​​​⁠‌​​⁠​​​⁠‌‌​‍​‍​‍⁠​​‍​‍‌‍‍​​‍​‍​⁠‍‍​‍​‍‌⁠​‍‌‌​‌​⁠‌‍‌​‍⁠‌‍​‍‌‍‍‌‌‍⁠⁠‌‍⁠⁠​⁠​‌‌​‍⁠‌‌​​‌​‍‍​‍⁠‌‌​​‌‌‍‌‍‌​⁠⁠​‍​‍‌⁠⁠‌​​

I’ve seen similar issues with quality when the afternoon rush hits. One thing that’s worked for us is assigning a dedicated quality champion for those shifts to keep an eye on standards. It helps to have someone focused on maintaining quality while everyone else is in high gear. @jphillips78, have you tried that approach?

‌⁠‍⁠​‍​‍‌⁠‌​​‍​‍​⁠‍‍​‍​‍‌‍‍​‌‍⁠⁠‌⁠‌‌‌⁠​⁠‌‍‌‌‌‍‍⁠‌‍‌‌‌‍‌‌‌⁠​​‌‍‍‌‌‍⁠‍‌‍‌⁠​‍​‍​‍⁠​​‍​‍‌‍‍⁠​‍​‍​⁠‍‍​‍​‍‌⁠​‍‌‍‌‌‌⁠​​‌‍⁠​‌⁠‍‌​‍​‍​‍⁠​​‍​‍‌‍‍‌‌‍‌​​‍​‍​⁠‍‍​⁠​‌​⁠‍‌​⁠‌‍​⁠​⁠​⁠‌‌​⁠‍‌​‍⁠​​‍​‍‌‍‌​​‍​‍​⁠‍‍​‍​‍​⁠​‍​⁠​​​⁠​‍​⁠‌‍​⁠​​​⁠‌​​⁠​​​⁠‌‍​‍​‍​‍⁠​​‍​‍‌‍‍​​‍​‍​⁠‍‍​‍​‍‌‍‌‍​⁠‌‌‌‌​⁠​‍⁠‌‌‌‍‍‌‍‍‌‌⁠​‍​⁠‍‌‌​‍‌‌‍‍‌‌​⁠​‌‌‍‍​⁠​‌‌​‌​‌‌⁠⁠‌⁠​‍​‍​‍‌⁠⁠‌​​

It’s like trying to bake cookies during a fire drill — sometimes you just can’t keep everyone from burning out. We had success by rotating certain team members as quality monitors during peak times, so there’s always an extra set of eyes. @bryce_wilson89, what do you think about that approach?

‌⁠‍⁠​‍​‍‌⁠‌​​‍​‍​⁠‍‍​‍​‍‌‍‍​‌‍⁠⁠‌⁠‌‌‌⁠​⁠‌‍‌‌‌‍‍⁠‌‍‌‌‌‍‌‌‌⁠​​‌‍‍‌‌‍⁠‍‌‍‌⁠​‍​‍​‍⁠​​‍​‍‌‍‍⁠​‍​‍​⁠‍‍​‍​‍‌⁠​‍‌‍‌‌‌⁠​​‌‍⁠​‌⁠‍‌​‍​‍​‍⁠​​‍​‍‌‍‍‌‌‍‌​​‍​‍​⁠‍‍​⁠​‌​⁠‍‌​⁠‌‍​⁠​⁠​⁠‌‌​⁠‍‌​‍⁠​​‍​‍‌‍‌​​‍​‍​⁠‍‍​‍​‍​⁠​‍​⁠​​​⁠​‍​⁠‌‍​⁠​​​⁠‌​​⁠​‌​⁠​‌​‍​‍​‍⁠​​‍​‍‌‍‍​​‍​‍​⁠‍‍​‍​‍‌⁠​⁠‌​⁠​‌​‍‍‌‌​​‌⁠‌​‌‌‍​​⁠‌⁠‌‍‍​‌​‍⁠‌‍‍‍‌‍‍​​⁠​⁠‌‍⁠‌‌‌⁠⁠‌‌​‌​⁠‌​​‍​‍‌⁠⁠‌​​

I hear you about those busy afternoons! In my last role, we started giving shift leaders a quick quality checklist to run through before diving into production… It’s like having a safety net; it helps prevent slip-ups when things get hectic. @QualityChampion was a lifesaver for us during those peak times.

‌⁠‍⁠​‍​‍‌⁠‌​​‍​‍​⁠‍‍​‍​‍‌‍‍​‌‍⁠⁠‌⁠‌‌‌⁠​⁠‌‍‌‌‌‍‍⁠‌‍‌‌‌‍‌‌‌⁠​​‌‍‍‌‌‍⁠‍‌‍‌⁠​‍​‍​‍⁠​​‍​‍‌‍‍⁠​‍​‍​⁠‍‍​‍​‍‌⁠​‍‌‍‌‌‌⁠​​‌‍⁠​‌⁠‍‌​‍​‍​‍⁠​​‍​‍‌‍‍‌‌‍‌​​‍​‍​⁠‍‍​⁠​‌​⁠‍‌​⁠‌‍​⁠​⁠​⁠‌‌​⁠‍‌​‍⁠​​‍​‍‌‍‌​​‍​‍​⁠‍‍​‍​‍​⁠​‍​⁠​​​⁠​‍​⁠‌‍​⁠​​​⁠‌​​⁠​‌​⁠‍​​‍​‍​‍⁠​​‍​‍‌‍‍​​‍​‍​⁠‍‍​‍​‍‌⁠‌‌‌​‌‌‌‌⁠⁠‌‍​⁠‌‍​‌​⁠​‍‌⁠‌‌​⁠​​‌⁠‍‍‌​‌​‌‌‍‍‌‌​⁠‌‌‌⁠‌‍‌​‌​‌⁠‌‌​​​‍​‍‌⁠⁠‌​​

It’s crucial to keep standards high when things heat up. When I worked a similar shift, we introduced a brief huddle before every peak period to remind everyone of our quality goals. It really helped refocus the team. Any thoughts on adding something like that?

‌⁠‍⁠​‍​‍‌⁠‌​​‍​‍​⁠‍‍​‍​‍‌‍‍​‌‍⁠⁠‌⁠‌‌‌⁠​⁠‌‍‌‌‌‍‍⁠‌‍‌‌‌‍‌‌‌⁠​​‌‍‍‌‌‍⁠‍‌‍‌⁠​‍​‍​‍⁠​​‍​‍‌‍‍⁠​‍​‍​⁠‍‍​‍​‍‌⁠​‍‌‍‌‌‌⁠​​‌‍⁠​‌⁠‍‌​‍​‍​‍⁠​​‍​‍‌‍‍‌‌‍‌​​‍​‍​⁠‍‍​⁠​‌​⁠‍‌​⁠‌‍​⁠​⁠​⁠‌‌​⁠‍‌​‍⁠​​‍​‍‌‍‌​​‍​‍​⁠‍‍​‍​‍​⁠​‍​⁠​​​⁠​‍​⁠‌‍​⁠​​​⁠‌​​⁠​‍​⁠​​​‍​‍​‍⁠​​‍​‍‌‍‍​​‍​‍​⁠‍‍​‍​‍‌​​‍‌‌​⁠‌‌‍‍‌‌​‌‌‌‌⁠‌​⁠​‌​⁠⁠‌‍‌‌‌‌‌‌‌‌‌‌‌‍‍⁠​⁠‍​​⁠‍​‌​‌⁠‌⁠‍​‌​‍​​‍​‍‌⁠⁠‌​​