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What are some of the most effective tools that you have used to prevent repeatable defects in a manufacturing plant?

A Quality, Safety and CIP  Manager asked, “What are some of the most effective tools that you have used to prevent repeatable defects in a manufacturing plant? We are trying to improve our FPY but continue with inconsistent results.” Scott’s and my response was:

Great leaps in quality come when you can characterize the process and understand what key factors lead to successful quality outcomes. It’s all about the process.
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blog_Quality and CPI

Other Good Answers to the Quality Question

Once again, the question Christopher posed on LinkedIn was: When does continual improvement actually begin?

A woman named, Uttia, said the following and I thought her answer was good:

First you need a process. Then you determine what you need to achieve in that process, then you need to set objectives in that process to achieve that. Then you need to set your objective and a proposed course of action to achieve that objective.
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