I have worked in Quality Control and Quality Assurance for most of my adult life. From the Aviation industry, Power Generation (Fossil and Nuclear), to Petrochem and Oil& Gas.
One thing I can tell you for a fact: You cannot inspect in quality. Quality starts with you base materials, components, and sub-assemblies.
Then your assemblers, craftsman, painters, warehouse/materials personnel have to be knowledgeable in their work and in the Quality Program.
This Quality Program HAS TO BE lived and breathed by every individual. This is especially applicable to the Production Management.
I have been a QC Manager and a QA Manager on many jobs. Some of these projects were Multi-Billion dollar project. (Anywhere from 1 to 12 Billion)
These had huge staffs of QC Inspectors, QA Inspectors, QA Auditors, etc.
While these folks may catch some of the problems it starts with the lowest person on the pole and runs to the top.
Git'er Done, Make My Production Numbers, We'll fix it later just leads to more quality problems.
Management HAS TO not only support but be the EXAMPLE of Quality and Safety first, and build it right the first time. Anything beyond that is lip service to deceive the customer and make themselves feel good.
Quality does have a price. It is not as high as production and the bean counters would have you believe.
Training and personal ownership of ones work has proven that costs can be maintained, quality is there, and productivity is also maintained.
I was raised by craftsman and quality inspectors. Schooled in it throughout my life. Experience has taught me and has shown me time and again the truth to what I have written above.
I have seen time and again manufacturers/fabricators who have quality problems will hire or promote the lowest paid person who "will do what is needed to keep their job" to provide an illusion that they have a quality program.
That is joke number ONE.
Yes, I am passionate about quality. I was taught my whole life to first build it, then you will know what it takes to make it the right way. Then you will know as an inspector what to look for when it was not done right.
Growing up I was taught and worked as a carpenter, welder, a/c installation, warehouse, oil tool manufacturing, machinist apprentice, etc. I needed to eat and help support our family.
In each case I worked up into the Quality Dept. The companies sent me to additional training courses and paid for me to test and receive my various certifications and licenses from those recognized code producing societies.
I have always pushed to increase my knowledge and experience in the Quality arena.
No matter my knowledge, expertise, or passion for quality one truth comes out.
I can help create, implement, and enforce the Quality program and requirements. But without the WHOLE team knowing what quality program is, how they implement and perform their part, and everyone supports it 100% it will NEVER happen.
