A Closed-Loop
Quality Mechanism.
At YMS, every quality anomaly becomes an opportunity. Our structured improvement process ensures every defect is identified, isolated, analyzed, and permanently resolved -- building safer silicone products for global brands.
PDCA
Continuous Loop
Quality Anomaly Identification.
Our multi-point inspection system detects deviations the moment they appear -- through in-line monitoring, operator reports, and SOP-driven sampling checkpoints.
Visual Inspection
Operators flag flashes, bubbles, color deviation, and surface defects in real time.
Dimensional Check
Tolerance monitored within ±0.1mm using precision measurement tools.
Performance Testing
Tensile, aging, tear, and impact tests performed per batch.
Customer Feedback
Market returns and complaints trigger immediate investigation protocols.
100%
Non-conforming items quarantined
Defective Product Isolation & Handling.
Once an anomaly is confirmed, affected units are immediately quarantined with red-tag identification. This prevents contamination of qualified stock and ensures full traceability.
Red-Tag Quarantine
Suspect goods are moved to a designated non-conforming area.
Batch Traceability
Lot numbers, mold IDs, and shift records are logged for full chain-of-custody.
Disposition Decision
Rework, scrap, or concession -- determined by QC leadership per SOP.
Root Cause Investigation & Analysis.
We apply proven engineering methodologies to uncover not just the symptom, but the fundamental source of every quality anomaly.
5-Why Analysis
Iteratively asking "why" to drill from symptoms down to the systemic root cause.
Fishbone (4M1E)
Analysis across Man, Machine, Material, Method, and Environment dimensions.
Data-Driven Verification
Design of experiments and statistical analysis confirm hypothesized causes.
Temporary Control Measures.
While root-cause investigation is ongoing, we deploy immediate containment actions to protect customer deliveries and prevent recurrence in the short term.
100% Full Inspection
Enhanced screening of all affected and adjacent batches until root cause is confirmed.
Production Hold
Affected molds or lines are halted pending engineering review and approval.
Customer Notification
Transparent communication with affected brand partners, including hold-ship advisories.
Corrective & Preventive Actions (CAPA).
Beyond fixing the current issue, we design systemic safeguards to prevent recurrence anywhere in the production system.
Corrective Action
Direct remediation of the identified root cause to eliminate the current defect.
- ✦ Process parameter adjustment
- ✦ Material supplier re-validation
- ✦ Operator re-training
- ✦ Tooling repair or replacement
Preventive Action
Systemic improvements to prevent similar defects in other products or lines.
- ✦ SOP updates and documentation
- ✦ FMEA risk register expansion
- ✦ Poka-yoke (error-proofing) design
- ✦ Cross-line audit rollout
Engineering & Mold Improvement.
Many silicone defects originate at the mold or process-engineering level. Our in-house tooling team redesigns, polishes, and optimizes molds to permanently resolve structural quality issues.
±0.1mm
Tolerance Control
45%
Toughness Improvement
64+
Molding Machines
ISO 9001
Certified SOP
Mold Redesign
Gate position, venting, and runner geometry optimized to eliminate flashes, short shots, and bubbles.
Process Parameter Tuning
Temperature, pressure, and curing-time windows re-validated with full-factor DOE testing.
Error-Proofing (Poka-Yoke)
Physical fixtures and sensors added to make incorrect assembly or placement impossible.
Improvement Effectiveness Verification.
No improvement is accepted until data proves it works. We verify, measure, and track performance before closing any CAPA.
Pilot Production Run
A small pilot batch (typically 500-2,000 units) tests the improvement under real production conditions.
Statistical Validation
Defect rate (PPM), Cpk, and process stability indicators are compared before and after improvement.
Extended Monitoring
30-90 day post-implementation monitoring confirms long-term stability before closure.
Formal Closure & Sign-Off
QC Manager and Engineering Director jointly sign off on the CAPA report, moving it into the knowledge base.
Experience Documentation & Standard Update.
Every improvement becomes institutional knowledge. We update SOPs, train teams, and build a living quality playbook.
SOP Revision
Standard Operating Procedures updated with new control points, parameters, and inspection criteria.
Team Training
All relevant operators, QC staff, and supervisors receive hands-on retraining on the updated standards.
Lesson-Learned Database
Every closed CAPA is archived in a searchable repository used for new project risk reviews.
FMEA Register Update
Failure Mode & Effects Analysis documents are expanded with newly identified risk scenarios.
Cross-Line Rollout
Proven improvements are deployed across similar molds and product families, not just the originating line.
KPI Dashboard
Real-time quality KPIs track defect rates, CAPA closure times, and recurrence prevention effectiveness.
Submit a Quality Improvement Project.
Have a quality concern, a product that needs refinement, or a new OEM/ODM project? Our engineering team will respond within 24 hours.
Prefer direct contact? Email us at edwin@gd-yums.com or WhatsApp +86 134 1898 3587