22.10.2017 Author: Zehnder Clean Air Solutions

Three main causes of product quality issues

Manufacturers have to be aware of the impact that product quality issues can have on a business. If your offering isn’t quite what your customers expect, they will likely be dissatisfied and rejection rates will increase. Should you fail to maintain product quality, you run the risk of negatively impacting your production costs – after all, you are manufacturing items that cannot be sold.


Why high rejection rates matter

Rejection rates matter because defective products are expensive for businesses. However, as noted in the Tooling U-SME Manufacturing Insights Report many manufacturers struggle to avoid product rejections. Some 16 % of those surveyed indicate that their scrap and rework rates account for 4 % of sales or higher – this means a $50 million plant, for example, will effectively waste $2 million just for the sake of revising or discarding products.

These costs include the expense of reworking the product’s raw materials and the labour involved in doing so – alongside shipping and logistics costs. Product quality issues can become expensive for your business: both in terms of ensuring customers are given a replacement or a refund, and in terms of your company’s reputation. 

It’s essential that you do everything in your power to make sure that your business maintains top product quality. If you don’t know what’s causing your product quality issues, we’ve identified their three most common causes below.


1. Particle inclusions

Surface treated parts – including painted, powder coated, galvanized and foil or plastic-coated parts –  are often rejected because of dust accumulating during the treatment process. This happens because production areas aren’t kept dust-free – allowing loose particles to gather on the surface of the part during the treatment process. When this happens the part is no longer perfect and you have to discard it.


2. Machinery malfunction

Your product rejection rate will be significantly lower if you can keep your machinery functioning properly at all times. Equipment malfunction can happen at any time, but not for any reason. Most often, it occurs as a matter of neglect: caused by a lack of maintenance, or dust settling on your equipment and staying there.


3. Processing problems

An efficient manufacturing process will help you maintain product quality. However, if machinery malfunctions are causing problems for your raw material processing operations, or if there are other inefficiencies in the way you process raw materials into goods, you will struggle to keep your product quality up. This will cause your rejection rate to soar.


A high rejection rate can devastate a business, so avoiding product quality issues is essential. One way to safeguard the quality of your goods is by implementing an air purification system like Zehnder Clean Air Solutions. The system filters dust particles out of the air before it has the opportunity to settle. This means that you’ll experience less inclusions, machinery malfunctions and processing inefficiencies. This will be of great benefit to your business as a low rejection rate will save your business money on a daily basis and your corporate image will get a boost ­– which again translates into more customers and profit.


For more information on the benefits of Zehnder Clean Air Solutions, take a look at this page.