Do you have long production runs at an overseas factory that last weeks or months? Have you experienced issues that delayed the delivery of finished goods? Or are you working with a new product or factory and feeling nervous about hitting your production timeline?
If you answered yes to any of the questions above, production monitoring may be the tool you need to ensure a successful on-schedule production run. In this article and video, we explain how production monitoring works and how to determine if it is right for you.
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What is Production Monitoring?
Production monitoring involves sending an inspector or engineer to the factory throughout an entire production run, from receipt of materials and components through shipping. They monitor the status of production and identify issues that might affect quality or timelines.
This on-site presence ensures that the incoming raw materials and samples from production are checked. The inspector analyzes any defects or deviations from the standard and works with the factory to correct issues in real time.
This process is beneficial for large production runs that span weeks or months to ensure the buyer’s expected quality standards are consistently met throughout production.
Video: Production Monitoring Overview
Watch this video for an overview of production monitoring, its benefits, and how it compares to inspection. We also explain how our approach to these projects and how to know if this tool is right for your situation.
The Key Benefits to Consider
Some of the key benefits of production monitoring are:
- Quick Resolutions: When timelines are tight, having an expert on-site to identify issues early allows for quicker resolutions.
- Process Improvements: The inspector or engineer can identify issues in the production process and propose solutions for better efficiency and quality.
- Enhanced Visibility: Get detailed daily updates on the status of all production steps to identify bottlenecks that may delay the timeline.
- Factory Accountability: Verify that the factory has the capacity to hit the targets they have set and is on track to do so.
This service goes beyond mere inspection. It involves ensuring that the factory addresses issues and makes process improvements. It also provides visibility and accountability throughout the manufacturing cycle—from the time an order is placed to when the goods are shipped.
Production Monitoring vs. Inspection
There are clear differences between production monitoring and quality inspection.
- Broader Focus: Production Monitoring has a broader focus on the entire production process, while inspection focuses more narrowly on a specific sample.
- Longer Timeframe: It can involve spending multiple weeks at the manufacturing facility, from the receipt of materials through assembly, packaging, and container loading.
- Not Just Quality: It typically involves monitoring the status of production, how many products are in process, and what stages they are at.
- Root Causes: The inspector/engineer analyzes each step of the production process and looks for issues that might be occurring that might affect the end product.
Production monitoring is process-driven and is most effective for long production runs with high quantities.
How We Approach These Projects
At Insight Quality, we approach production monitoring projects as follows.
- Discuss Current Issues: We work with clients to understand the specific issues they face, whether they are related to quality, shipping deadlines, or a combination of both.
- Review Factory Processes: We ensure that we have the right subject matter expert who can work with the factory to review and understand the nuances of the factory’s production methods and workflow.
- Begin Monitoring Production: Our approach involves ongoing communication with the factory to monitor production based on the client’s expectations.
- Ongoing Data Collection: We continuously collect and review data from the production line.
- Resolve Any Issues: The goal is to catch any issues early, communicate them promptly, and work with the factory to implement measures to address and solve them.
- Communicate With Client: We keep our clients updated based on their preferred communication cycle, whether daily or weekly, to ensure that everyone is aligned on the production progress and quality.
By following these steps, we can discover and resolve issues as they occur and always keep clients in the loop.
Who Should Consider These Services?
Production monitoring is ideal for companies with large production runs that want to minimize quality issues and shipping delays. It is also suitable for those with factories willing to partner closely, allowing a third party to be on-site to help identify and solve potential issues. This partnership approach ensures that production orders meet quality requirements and are shipped on time.
Production Monitoring Services: Insight Quality Can Help
If you think you might benefit from production monitoring services, contact us. We will be happy to discuss your current situation and formulate a plan to meet your needs.
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