Built In Quality (BIQ)

Built-in quality (BIQ) is a principle that emphasizes designing processes and systems to prevent defects and errors. Check at every stage, ensuring that quality is inherent in every task. It leverages standardization, error-proofing (poka-yoke), and feedback loops. This ensures that each step in the process is carried out correctly the first time.

Built-in Quality is a strategy to control the faults and issues that disturb the product quality. It also refers to a systematic approach aimed at ensuring that quality is ingrained. This strategy has some tools to monitor the quality.

These are essential production quality control tools. Their use is straightforward and the results are good. Actions and decisions are taken urgently for product quality monitoring in these tools.

Working Principles.

The quality is undercontrol in every step of a product’s lean manufacturing process. Rather than relying on post-production inspections or quality checks. The concept focuses on embedding quality throughout the entire value stream. From design to delivery, to prevent defects and inefficiencies at the source.

Purpose

The main purpose of Built-In Quality is to:

• Control defects Find out the defects that disturb the quality rather than correct them after the fact.
• Increase efficiency by reducing rework and delays caused by quality issues.
• Enhance customer satisfaction through consistent delivery of high-quality products.
• Empower workers to own quality at every step, promoting accountability and continuous improvement.

Importance

1. Cost Reduction:
   • Addressing defects early in the process significantly reduces the cost of rework, scraping, and warranty claims.
2. Customer Satisfaction:
   • Consistent quality builds trust with customers and reduces complaints, ensuring repeat business.
3. Continuous Improvement:
   • BIQ promotes a culture of learning and improvement, where workers identify and eliminate the root causes of quality issues.
4. Efficiency:
   • Minimizing defects and errors reduces downtime and increases throughput, leading to higher productivity and faster delivery times.
5. Employee Engagement:
   • Workers are more engaged when they are empowered to take ownership of quality, which improves morale and reduces turnover.

Built-In Quality tools

Here are some tools that are used for this purpose and their use is very simple.

Green Board:

In this board select a fault that occurs again and again and impacts the product quality.

1. Standardized Processes:
   • Create clear, repeatable processes that ensure quality is built into every step. This includes standard work instructions, checklists, and best practices.
2. Error-Proofing:
   • Introduce mechanisms that prevent errors from occurring or make them immediately obvious. Examples include using fixtures that only allow parts to be assembled in the correct way or sensors that detect missing components.
3. In-Process Checks:
   • Instead of waiting for final inspections, integrate quality checks throughout the production process. Workers should have the tools and training to verify the quality of their work as they go.
4. Root Cause Analysis:
   • When defects do occur, use tools like the “5 Whys” or “Fishbone Diagrams” to identify and address the root cause, ensuring that similar defects do not happen again.
5. Cross-functional collaboration:
   • Involve all stakeholders, including design, engineering, production, and quality teams, in the development process to ensure that quality considerations are addressed at every stage.
6. Feedback Loops:
   • Create feedback mechanisms so that workers receive immediate information about defects or deviations from standards, enabling quick corrective actions.
7. Training and Development:
   • Continuously train workers on quality principles, techniques, and tools. This empowers them to make informed decisions and maintain high standards.
8. Visual Management:
   • Use visual tools such as andon lights, charts, and dashboards to monitor quality metrics in real time and make problems visible so they can be addressed promptly.

Conclusion

Built-in quality is essential for any organization focused on delivering high-quality products efficiently and effectively. By embedding quality at every step, companies can reduce costs, increase customer satisfaction, and foster a culture of continuous improvement. The success of BIQ depends on clear standards, proactive error prevention, and a commitment from all employees. Employees should take ownership of quality.