What is Production Quality Assurance?
Production Quality Assurance - (From the customer prospective) Is the state of the art inspection review of production processes know as 6 Sigma, 8D, Kaisan (old school, 1947) or similar process review systems for suppliers.
These inspections are made with the arrangement of the supplier using proven production systems, reviewing existing processes, analyzing output against given expectations and performance goals set by both the customer and the supplier. After review, analysis is made and goals are set to improve given parameters,
6 Sigma is covered here.
Calibrated acceptance inspection tools and techniques covered in one of many standards including ISO, AS and / or customer specific Q standards. Tolerances are measured, recorded and stored or supplied to the customer for review as required by SOW's.
Software is now available to perform most of the tedious tasks in the FAI process, a few are:
- Visual FAIR Discussions on these can be foundhere
Review of the FAI information is key to government acceptance, correct application of specifications, materials & approvals are scrutinized, reviewed and approved based on information provided by the contractor.
Full review of each detail is made to accept / reject the First Piece during its inspection, these parts are usually kept for a minimum of 1 year, sometimes 2 depending on the Q notes.
Daily reports are written for each visit to the supplier covering a wide range of standard items or issues along with any special interest requests made. Quarterly progress reports and other specialized reports are created upon request.
Machine manufacturing & tooling has become a specialized skill requiring specialized education & certification due to CNC automation.
QA-Israel continues to work with outstanding / qualified contractors to verify production, schedules & resources for our clients, all of which is delivered in daily weekly and quarterly reports to our clients who demand receive US representation throughout the Middle East and Europe through our web infrastructure called InSight.
The 8D system to alleviate failures & reflect assertiveness in responsive QC issues.
Production continues to be the biggest hurdle in the Israeli economy and indeed almost every production floor has issues. Even the IMF notes this in their latest assessment of the Israeli Economy.
The 8D process Outlined:
Before the actual work starts, the problem must be identified and brought to the point. The individuals in charge should be identified.
Go to the problem in the team: place a small team of people together who have the appropriate process and product knowledge, time, level of cooperation, competence and knowledge of the note ended techniques to solve the problem and corrective action In order to launch. The team must have a sponsor.
Describe the problem: Use the problem analysis, to define the problem of internal / external customers as closely as possible. Working out the core of the problem and Quantify it. Collect and analyze data using statistical methods.
What is the real problem?
By managers or customers often only symptoms are described. The real problem has to be identified by the team and will be described in detail.
Essential components of a problem is the object, part of production, etc., or a person Deviation, it can be a difference between the desired and the current IS IS can be measured. This deviation must also withstand statistical analyzes.
Immediately take action
Induce temporary mitigation measures and check their effectiveness: Induce measures to keep the effects of the problem of internal / external customers as possible, until a permanent solution is found. Constantly check the effectiveness of this
temporary measures and arrange leave any future action.
How to protect customers from the consequences of the problem?
An essential source of information is the problem description
Determine the root cause (s) and see if it really is the root cause (s) is / are: check whether the problem can be solved with the participants of the team, and modify it if necessary. Use the problem analysis in the search for all possible causes,
could explain the occurrence of the problem. Determine the potential (s) cause (s) and check comparisons with the problem specification and the available data whether a possible cause
probable cause is. Evidence most likely cause by testing and experimentation as the underlying cause.
Usually the most difficult step in the process.
The underlying cause must be proved to be encircled and then. Sometimes succeeds no longer proved. But you should make sure that the suspected cause explains all the facts
Lays down corrective action and review their effectiveness: Test if the problem can be solved with the participants of the team, and modify it if necessary. Search all possible measures by removing the cause and the problem could be solved. Choose using decision analysis the most balanced (solve) (n) long-term (s) Corrective Action from (n) and prove by appropriate tests that the chosen (n) long-term (s) Corrective Action triggers (s) the problem from a customer perspective really and No adverse side effects (have).
Perform the corrective action (es) and check your effectiveness: Test if the problem can be solved with the participants of the team, and modify it if necessary. Create an action plan for implementation of the selected corrective action (s) and determine by which ongoing checks to ensure that the problem has been rectified really. The plan must be confirmed by applying the analysis Potential problems or FMEA. Looking To Action plan by observing the impact and lead where appropriate by the cautionary or Eventualmaßnahmen.
Determine measures to prevent a recurrence of the problem: Check if the problem can be solved with the participants of the team, and modify it if necessary. Change the management and control systems, instructions and customary practices, to prevent the same or similar problems on this or other points recur. Identifying opportunities for improvement and guide process improvement initiatives designed.
Decent performance and success of the team: Complete the teamwork; acknowledge the combined efforts and experience and be happy with the success. Think about whether the results should be published.
Try it at: http://www.8dreport.com 45 day free trial.8D work sheet PDF
More 8D info at: http://elsmar.com/8D/ &http://en.wikipedia.org/wiki/Eight_Disciplines_Problem_Solving