Quality Control Systems That Grow With a Small Product Business
Is your quality control keeping up with your growth?
Every small product business begins identically. You get some orders. Someone eyeballs each unit individually. All looks good. Then orders double. They double... then double again. Now the old method of inspection doesn't cut it anymore.
Here's the problem: Quality problems cost big bucks. In fact, many manufacturers estimate quality-related expenses to be 15% to 20% of sales. Those are dollars going straight into scrap, rework and returns.
The good news? You can create a quality control system that scales with your business.
Here's how to do it...
Inside this guide:
Why Quality Control Breaks As You Grow
The 3x Stages Of A Scalable QC System
Signs It's Time To Upgrade Your Tools
Mistakes That Hold Small Businesses Back
Why Quality Control Breaks As You Grow
In the early stages of a business, quality control often resides in the mind of one individual. They know which pieces fail frequently. They know which measurements are most critical.
But that doesn't scale.
With increased volume, manual inspections become slower and errors begin to creep in. Threaded components are a prime example. Pitch, major diameter and thread angle are difficult to inspect manually with gauges. Inspections can be time consuming and two inspectors may produce two different readings from the same component. That is why thread measurement software is becoming essential for the high volume shop floor. Automated thread measurement takes seconds to capture the critical features of a thread. It eliminates human interpretation between operators and stores every measurement for trend analysis.
Finding qualified staff to perform manual verification tasks is becoming increasingly difficult as well. Over 72% of manufacturers report that their greatest need is for skilled production workers such as technicians and machinists. Industry analysts have also cautioned that as many as 1.9 million manufacturing positions could go vacant should the skills gap persist.
Fewer skilled hands + more orders = more defects. It really is that simple.
The 3x Stages Of A Scalable Quality Control System
Great quality control systems don't just happen overnight. They evolve… and each phase should align with the current state of your business.
Pick the stage that fits you today, then plan for the next one.
Stage 1: Build Simple, Written Standards
Every good system starts with clear rules.
Make a list of what defines a "good" product. Prior to making any purchases, know:
To start, what is your goal in purchasing tools?
Key measurements and tolerances
What to check and how often
What to do when a part fails
Simple is good. A one-page list that is utilized is better than a 50-page list that sits on a shelf.
Documented standards allow anyone on your team to know how to follow them. Dependability of quality no longer relies on one individual. And another thing... Standards written documents are free. It just takes an afternoon and someone knowledgeable about the product.
That's a big win.
Stage 2: Swap Manual Checks For Software
This is where most small businesses see the biggest jump in results.
Calipers and thread gauges are ok when producing a couple hundred parts. However, when you start increasing production they become a huge constraint.
Measurement software corrects that. It allows faster inspection, repeatable results and automatic data capture.
Here's why that matters...Scrap and rework costs alone can amount to up to 2.2% of annual revenue. To a marginal small business, that's the difference between red and black. The sooner issues are identified, the less scrap there will be.
When choosing software, look for tools that:
Are easy to learn (so new staff get up to speed fast)
Measure several features at once
Export reports your customers can read
Can grow with more users or machines later
Don't automate everything right away. Focus first on those items that are the biggest pain or take the most time to check.
Stage 3: Connect Your Quality Data
Now things get really interesting.
After digitizing your measurements, you can tie them into the rest of your business operations. You'll then be able to identify trends before they become actual issues.
For example: If a machine continuously produces parts near one end of the tolerance band, the trend data will reveal it. You can adjust the machine before it produces defective parts.
That's the shift from finding defects to preventing them.
Connected data can also simplify your life when customers demand proof of quality. Rather than searching through paper records, you simply run a report in minutes. Larger customers often require this type of tracking before they place big orders. Having it can help you land new business as well.
Pretty cool, right?
4x Signs Your Quality Control Needs An Upgrade
Not sure if it's time to level up? Watch out for these warning signs.
Inspection is slowing shipping. If you have completed parts sitting in a queue waiting for inspection, your quality process is creating a bottleneck.
Different inspectors produce different results. Typically, this indicates a heavy reliance on personal judgment in tools or methodology.
Customer returns are inching up. A slight increase should be warning you that defects are getting through.
You can't retrieve historical data quickly. If you have to go through file cabinets to find the answer to a customer complaint, you have a data retrieval problem.
Spot two or more of these? It's time to move to the next stage.
Mistakes That Hold Small Businesses Back
Building a quality system doesn't always run so smoothly. Learn the mistakes most small business make...
Purchase of tools before standards are defined. You cannot standardize a process until it has been documented. Define your standards, then purchase tools that fit your needs.
Skipping training. If your team doesn't know how to use a tool, it's pretty useless. Remember to schedule time for training whenever you implement something new.
Neglecting the numbers. Gathering metrics is only part of the task. Schedule time every week to analyze trends and respond accordingly.
Quality control is not a project you do one time. It's a practice that should evolve with your company.
Bringing It All Together
Quality control systems that scale with your business will save you time and money and a lot of headaches. The key is implementing them one step at a time, rather than trying to do it all at once. Here's a quick recap:
Write clear standards first
Replace slow manual checks with measurement software
Connect your data so you can prevent problems
Watch for the warning signs and upgrade when needed
Winning businesses think about growth before problems arise. Begin with what fits you today ... then grow from there.
Rinse and repeat!