How Your Quality System Might Be KILLING Your Business

The moment this supervisor discovered 80% of their products were out of spec—despite 'perfect' quality reports. Is your averaging system hiding the same horrifying truth?

I recently witnessed something so disturbing in a manufacturing facility. What I uncovered wasn’t just a quality issue—it was a full-scale assault on customer trust.

Let that sink in.

⚡ Fast forward to a manufacturing floor where products are being shipped to unsuspecting customers. The quality team is smiling, confident their products meet specifications. Their inspection records show everything passing with flying colors.

Then came the bombshell.

💣 THE SHOCKING REVELATION

When we measured individual products instead of batches, we discovered the horrifying truth:

• 40% of products were horribly underweight

• 40% were wastefully overweight

• Only a pathetic 20% actually met specifications

This isn’t just poor quality control. This is a CRIME against your customers.

🔄 THE AVERAGING DECEPTION might be killing your business. THE AVERAGING DECEPTION could be destroying your reputation.

Here’s what was happening: This company was weighing products in batches of ten and recording only the average. On paper, everything looked perfect—but in reality, 80% of their products were OUT OF SPECIFICATION.

⚡ Fast forward to their customers opening boxes of inconsistent products. Imagine their disgust. Imagine their phone calls to competitors.

Averaging can be the silent killer of quality systems. It masks variation that your customers experience with every single product.

💣 THE SOLUTION THEY DON’T WANT YOU TO KNOW

Here’s what the quality establishment won’t tell you: ISO 9001 implementation doesn’t have to be complicated or expensive.

Through Cornerstone Engineering’s customized system development, this client:

1. Implemented pre-control charts to track INDIVIDUAL measurements

2. Eliminated the averaging deception

3. Discovered the true capability of their process

4. Regained the trust of furious customers

🔄 THE AVERAGING DECEPTION was killing their business. THE AVERAGING DECEPTION was destroying their reputation.

Until they stopped it.

⚡ Fast forward one more time: The same company, six months later. Customer complaints? ZERO. Returns? ELIMINATED. Profit margins? SOARING.

🎯 YOUR BUSINESS IS AT RISK RIGHT NOW

Ask yourself:

• Are you measuring what your CUSTOMERS experience?

• Or are you hiding behind averages that mask the truth?

The choice is yours: Continue committing THE AVERAGING DECEPTION, or contact us here at Cornerstone Engineering today for:

• Customized system development

• Gap analysis that reveals the TRUTH about your processes

• Internal auditor training that catches these deadly mistakes

Cornerstone Engineering, Training, and Consulting LLC helps companies achieve continual improvement and compliance with ISO standards. Their globally recognized ISO templates, customized system development, audit programs, gap analysis, and internal auditor training have helped countless companies improve quality, on-time delivery, and customer satisfaction. Visit www.ce-q.com to learn more.