We’re the manufacturer that eliminated our final inspection positions. Are we crazy? No, we simply realized that the quality check role was too removed from the process to be effective. So we put quality control back where it belongs – with everyone during the process. Our quality at the source philosophy makes every Ace cell member wear the quality control hat. All operations and in-process inspections are the responsibility of every team member. Each production cell tracks products that leave their cell.
Seeing is believing with our First Time Through System.
Getting it right the first time is key to the Ace process. Our First Time Through System is easy to explain – and easy to see.
Team performance and quality performance are the same. Every part is inspected during the process. Every team member records the part based upon a checklist for the part and process type. Receiving teams can reject a part for quality issues and send the part back.
Visual Management is Key
The visible signs of the quality focus include lines along the floor that connect teams, and hanging signs that list the standards of quality for each cell. Overall satisfaction among cell members is high because they’re part of the decision-making process.
Weekly team scores are posted on the Team Boards and Main Score Board located in every visible area of our shop. These boards are key reminders of what we expect at Ace of every associate – they reinforce and drive specific behaviors such as taking responsibility for    quality and the team’s performance. Winning teams are rewarded weekly for their performance.
We also created Quality Cell Point Leader roles responsible for quality, throughput and on-time delivery. Each Leader serves a three-month rotation so that more associates have the opportunity to develop leadership expertise and more fully understand key performance areas.
Today, important production decisions are made at the shop floor, which enables our continuous improvement culture. To date we have tracked significant improvement in initial and overall product quality – without requiring non-value added inspection personnel.