Early Warning is a core feature of many other quality systems but how effective does it work in those systems? If manufacturers identify product issues 60 months after release on a regular basis and they use quality systems, those systems are not effective and only serve to check off the “We use a Quality Management System” box.
GradeQ identifies issues other systems take 60 months to identify in only 1 to 3 months. Unlike what many think, bad components in challenged products typically fail at constant rates from day 1 of production. They do not all operate for years perfectly then fail on a large scale from 3 to 4 years. Many believe first failures are due to infant mortality and failures follows the Weibull bathtub curve as that’s what’s taught in reliability engineering. While this is true in controlled environments, this is not true in the field. Anyone who has worked field issues knows this is not true simply because field issues are not caused by one failure mode or one cause. Issues are caused by many, many things some of which have no relationship to the product. Have you ever received a present for Christmas, didn’t need it, and returned it for credit? I have.
Identifying field issues early can easily save 95% or more of the cost of the issue. This allows businesses to fix issues in the first 5% of a product’s life-cycle effectively eliminating the need for major product return programs or even notifying customers. This is because the issue will be at or below acceptable field failure rates by the time it is reported to or analyzed by government and other agencies. Imagine not having to write service advisories because they are not needed!
While there is no guarantee every field quality issue can be detected on the first week of production, most if not all issues can be identified a few months after problems present themselves and causes failures in the field.
GradeQ provides the best Early Warning in the industry.