1. Floor audit.
Put some product engineers into the assembly and subassembly areas.Have them compare what’s actually being built to the bill of material.They should work closely with not only the foremen but also with the assemblers. Correct errors as they’re discovered.
2. Office/factory review.
Form a team of people from the plant floor plus engineers, materialplanners, and perhaps cost people to review the bills jointly, sitting around a conference table. The question to be asked: “Is this the way we build it?” Again, correct errors as they’re found.
3. Product teardown.
Take a finished product apart. Compare the parts and pieces on the table with the computer listing and correct the errors. This is a good approach for many companies, but may be impractical if the product is a jet airliner. Another shortcoming can be the difficulty in recognizing subassemblies.