Prompting for Quality Control and Problem-Solving
Quality issues are expensive. AI can help you troubleshoot faster and implement better quality systems.
Scenario: Analyzing Defect Patterns
Good prompt: "I'm seeing an increase in surface finish defects on aluminum parts coming from our grinding operation. Defect rate has increased from 2% to 7% over the past month. The parts are ground on three machines (A, B, C) by operators across three shifts. Variables that could be relevant: coolant concentration, grinding wheel condition, feed rate, operator technique, material lot variations. Walk me through a systematic root cause analysis approach to identify the source of these defects. What data should I collect first, and how should I analyze it?"
The AI will guide you through structured problem-solving: data collection strategies, hypothesis testing, statistical approaches, and isolation techniques.
Follow-up prompts:
- "Here's the defect data broken down by machine and shift: [paste data]. What patterns do you see, and what do they suggest about root causes?"
- "Based on this analysis suggesting coolant concentration as a likely factor, design an experiment to confirm this hypothesis and determine the optimal concentration range."
- "Create a control plan to prevent this issue from recurring, including monitoring frequency, control limits, and corrective actions."
Scenario: Implementing Statistical Process Control
Good prompt: "I want to implement SPC on our injection molding process for a critical dimension that specs at 25.0mm ±0.2mm. We produce approximately 10,000 parts per day across 4 molding machines. I'm not an expert in SPC. Explain what I need to do in practical terms: what type of control chart to use, how to establish control limits, how many samples to measure and how often, how to interpret the charts, and what actions to take when we see out-of-control conditions. Give me a step-by-step implementation plan."
This prompt acknowledges your knowledge level and asks for practical implementation guidance, not theoretical explanations. You'll get actionable steps you can execute immediately.
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