Quality engineer is a critical role in manufacturing industry. He helps to ensure product quality consistency, customer satisfaction, and legal or regulatory compliance in manufacturing. However, even the most experienced quality person can fail and got into avoidable traps that affect your quality outputs. In this article, we’ll explore the top 10 mistakes quality engineers should avoid in manufacturing projects and get practical tips to avoid those and keep on your quality engineer journey.
Whether you’re a expert quality professional or just starting out, these quality engineer tips will help you to keep away from some common mistakes in quality control.
1. Neglecting Process Audits
One of the biggest observation is skip to perform process audits. Sometimes it is just a checkbox activity. Regular audits help to make sure that the process is followed as per planned and find out gaps/problems before they become customer issues.
👉 Read more: Types of Audit in Manufacturing
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
|---|---|---|---|
| Skipping process audits or treating them as a checkbox activity. | ⮞ Time constraints ⮞ Overconfidence in processes ⮞ Lack of understanding of audit purpose | ⮞ Missed process deviations ⮞ Repeatative customer complaintsNon-conformance (NC’s) in future audit | ⮞ Schedule regular Layered Process Audits (LPA) ⮞ Engage all process owners during the audit ⮞ Document findings and track closure of actions |
2. Overlooking Control Plan Accuracy
The control plan is your blueprint for quality assurance. Sometimes control plan not getting updated due to design or process changes. Therefore, it is no longer match with current process. If the engineers fail to update or review, then it leads to incorrect inspections and control points.
👉 Recommended read: Control Plan: A Complete Guide
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Using an outdated or generic Control Plan that no longer matches the current process. | ⮞ Engineering changes not communicated ⮞ Control plan not reviewed after FMEA updates | ⮞ Wrong checks on the shop floor ⮞ Parts may go unchecked or under-checked ⮞ Higher defect escape rate | ⮞ Always update the control plan after any design or process change ⮞ Review control plans during internal audits ⮞ Link control plans with PFMEA for consistency |
3. Poor Communication with Cross-Functional Teams
A quality engineer must be the bridge between different functions such as design, production, and supply chain. The mistake of failing to communicate clearly during engineering changes or quality issues can cause a serious production failure.
💡 Tip: Always try to document and circulate minutes of meetings after review meetings and cross-functional discussions.
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Not effectively sharing quality data, changes, or risks with other teams. | ⮞ Working in silos or your own ⮞ Assumption that others are already informed | ⮞ Rework due to misalignment ⮞ Delays in corrective action ⮞ Blame culture between departments | ⮞ Conduct regular Quality Review Meetings ⮞ Share actionable insights, not just reports ⮞ Encourage open communication across design, production, and supplier quality teams |
4. Ignoring FMEA Updates
Failure Modes and Effects Analysis (FMEA) is a living document. Many quality engineers create it once and forget about it. Not updating the FMEA after customer complaints, line changes, or field issues is a major mistake. It will lead you to have a major non-conformity.
👉 Learn more: FMEA Creation and Updates
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Treating FMEA (Failure Modes and Effects Analysis) as a one-time document. | ⮞ Lack of ownership ⮞ Time pressure to close APQP stages ⮞ Poor linkage with actual process learnings | ⮞ Failure modes go unidentified ⮞ Inaccurate risk prioritization ⮞ No preventive actions applied | ⮞ Update FMEA after every customer complaint, warranty issue, or process change ⮞ Assign clear ownership for FMEA updates ⮞ Conduct regular FMEA reviews in project milestones |
5. Not Responding Promptly to Warranty Complaints
Delaying analysis or corrective actions for warranty complaints can damage your customer relationships and your company’s reputation. You should do immediate response with a root cause and preventive action on every complaint.
👉 Dive into: Warranty Complaint Handling Procedure
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Delaying response or investigation of warranty complaints. | ⮞ Overloaded with shop-floor issues ⮞ No system for tracking complaints effectively | ⮞ Loss of customer trustCostly penalties ⮞ Repeat issues in the field | ⮞ Log every complaint with date, part number, and failure mode ⮞ Prioritize complaints with severity and frequency ⮞ Respond within 24–48 hours with a containment plan |
6. Weak Root Cause Analysis / Problem solving
Problem solving is one of the must have skill for every quality engineer. Jumping to conclusions without root cause analysis and using proper tools like 5-Why or Fishbone Diagram leads to recurrence of problems. A surface level RCA is one of the most damaging mistakes in quality control.
💡 Tip: Always validate root cause with data and involve the process owner.
👉 Related post: 8D Methodology in Manufacturing
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Jumping to quick fixes instead of identifying the real root cause. | ⮞ Pressure to close issues fast ⮞ Lack of training in problem-solving tools | ⮞ Same problem repeats again ⮞ Increased cost of poor quality (COPQ) ⮞ Low customer satisfaction | ⮞ Use structured tools like 5-Why Analysis, Fishbone Diagram, and 8D Reports ⮞ Validate the root cause with data and shop-floor evidence ⮞ Cross-check your findings with production and maintenance teams. |
7. Incomplete PPAP Documentation
Submitting incomplete or inconsistent Production Part Approval Process (PPAP) documentation can lead to rejections and supply chain delays. Make sure all 18 elements also customer specific requirements are properly reviewed and verified in your PPAP submission.
👉 Popular resource: Dimensional Results in PPAP
👉 Related: Customer Engineering Approval in PPAP
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Submitting PPAP (Production Part Approval Process) files with missing, outdated, or inconsistent documents. | ⮞ Misunderstanding the full PPAP requirements ⮞ Last-minute rush before customer submissions | ⮞ PPAP rejection ⮞ Shipment delays or holds ⮞ Reputation damage with OEM or Tier-1 | ⮞ Maintain a checklist of all 18 elements ⮞ Get approvals for Engineering Change Notes (ECNs) and AAR in advance ⮞ Use internal reviews before final PPAP submission |
8. Lack of Supplier Quality Monitoring
Supplier management helps to maintain control over your supplier. Here the supplier quality behavior is track. Ignoring poor supplier quality performance until a problem happen is a costly error. Regular supplier audits, scorecards review, and incoming inspections help to maintain part quality.
💡 Tip: You should develop a supplier risk matrix and prioritize based on criticality.
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Only responding to supplier problems when a defect reaches your line or customer. | ⮞ Limited manpower ⮞ No regular supplier audits or scorecards | ⮞ Line stoppages ⮞ Inconsistent incoming part quality ⮞ Blame games with suppliers | ⮞ Implement a Supplier Rating System ⮞ Conduct periodic audits and incoming inspections ⮞ Train suppliers on your expectations and critical features. |
9. Failure to Use Statistical Tools
Statistical tools are the backbone of process improvement. Neglecting statistical tools like SPC (Statistical Process Control) or Process Capability Analysis leads to missed signals of process drift or variation.
👉 Use our tool: Process Capability Calculator
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Ignoring the power of SPC (Statistical Process Control), control charts, and capability studies. | ⮞ Lack of training ⮞ Underestimation of data insights | ⮞ Late detection of process variation ⮞ Non-capable processes delivering poor parts ⮞ Defective product shipped to customers | ⮞ Regularly review Cp, Cpk, Pp, and Ppk values ⮞ Train shop-floor operators to understand control limits ⮞ Use software tools or spreadsheets to automate data analysis |
10. Skipping Layered Process Audits (LPA)
LPAs help to catch daily process deviations and strengthen accountability. Many quality engineers don’t implement/perform them correctly and treat Layer Process Audit as a formality and do for documentation only.
👉 Must-read: Layered Process Audits in Manufacturing
| What Is the Mistake? | Why It Happens: | Consequences: | How to Avoid: |
| Treating LPA as a formality or skipping the schedule altogether. | ⮞ Lack of buy-in from leadership ⮞ Poor scheduling and follow-up | ⮞ Operators deviate from standard practices ⮞ Processes drift from control over time ⮞ Reduced accountability on the floor | ⮞ Set a clear calendar with rotating leadership participation ⮞ Keep audits short (10–15 minutes) and focused ⮞ Use digital LPA checklists for real-time tracking |
Final Thoughts
Try to avoid these top 10 mistakes in quality control, it will help you to improve your performance and career success. Manufacturing industry are challenging day-by-day. As a quality engineer staying proactive, attentive, informed and consistent are key factors to grow.
Want to boost your skills and become an expert in manufacturing quality?
👉 Start here: Skills of Quality Engineer
I am a full time Engineer and Quality Professional with over 11+ years of experience in the automotive industry. My professional journey has started from a small enterprise quality inspector to a advanced quality expert. I am creating a good-quality content for engineers. Help them to grow in their career.Learn more here.
