Quality cost of 100% inspection on manufacturing processes: Advantages of using a simulation approach

Abstract

In manufacturing companies, quality costs can be quantified and reduced. Nevertheless, there are obstacles to their determination, restricting the ability of organisations to establish quality cost reduction programmes to become more competitive. The paper's objective is to propose a simulation approach to determine the quality cost of 100% inspection strategy. The proposed approach is developed in SIMIO and presents advantages over analytical solutions, such as the lower modelling effort and broader statistics than the expected quality cost. Results suggest that the graphic animation of the simulation model developed allows assessing the coherence of the model and adjusted to reality, thus contributing to greater acceptance of the model and consequent involvement of managers, contributing to a better estimation of quality costs.