Quick Quality Inquiry List in Production Campaigns
Speed pressure during campaign periods increases the risk of decreasing quality. Problems are caught early by keeping just 7 critical metrics per shift with a simple “query list”: product pass-through, waiting, visual acceptance, audio and consumption signals.
During the campaign, “something happened, how can we fix it?” approach is often late. Instead, working with an inquiry list that is established from the beginning and remains the same every shift shortens the response time.
Define the campaign scenario
Clarify the goal first: “Is speed increase, quality or delivery the priority?” Accordingly, if you decide based on the threshold, the team's interpretation will proceed with univocal data.
Critical 7 measurement areas
- First 10 pieces quality control after product transition.
- Consumption deviation measurement every 30 minutes.
- Comparison of gradual increases in line speed to the baseline.
- Control of sudden changes in filter and supply pressure.
- Visual acceptance rate after installation.
- Intra-shift distribution of open waiting time.
- Night shift vs. day shift.
Case analysis
If consumption increases by 1.4% within the first 2 hours of a campaign and at the same time there is line irregularity, the order of intervention is: first the speed level is frozen, a 10-minute mini observation is taken and a decision is made to accelerate again.
Short answer format: 7x7 questions
In order for the operator team to respond quickly, the following 7 questions are asked at the beginning of each shift:
- Was there a product change?
- What range was the open hold in?
- Is there a night shift note?
- How is the filter condition?
- When did the first visual deviation begin?
- At what time was the intervention triggered?
- Is there a transfer note for the next shift?
Product and process links during the campaign period
See technical parameters on product pages first for comparison and verification:
- Hot melt product sets – quality limits appropriate to campaign speeds
- Packaging glue products – edge banding and wrapping line scenarios
- EVA hot melt product details – rapid application and consumption behavior
- PO hot melt product details – resistance to temperature fluctuation
Quick Quality Inquiry List in Production Campaigns hakkında merak edilenler
How long does it take to notice a decrease in quality in the campaign?
Generally, consumption and visual deviation begin to increase together in the 30-60 minute period. Therefore, early measurement is very important.
Which signal is the first intervention signal?
It is not a signal per se, but the increase in consumption and visual degradation seen in two consecutive measurements.
Can maintenance data also be added to this list?
Yes. When read together with the monthly filter change period, the intervention accuracy rate increases.
How does the operator remember this?
Keeping the card short and steady, leave space for: product, temperature, speed, standby, consumption and notes. This order is easy to memorize.
For which cities is the campaign checklist useful?
For intensive production regions (Istanbul, Bursa, Eskişehir, Adana), the value of the plan increases, especially since the frequency of product transition is high.
Does the 7x7 method work during off-campaign periods?
Yes, it can also be used during night shifts and busy periods. Only target metrics (target speed, tolerance and control range) should be updated outside of the campaign.
Technical resources and verification
The content has been prepared in Turkish with the technical experience of Koçak Endüstri, based on the following manufacturer resources.
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