Free Infographic – Growing Manufacturing through Quality Processes

INCREASING THE BOTTOM LINE: HELP YOUR MANUFACTURING BUSINESS GROW By adopting quality control processes and standards you can improve your manufacturing business. This will help you reduce costs, reduce waste, deliver better quality products and meet customer expectations. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (IS) WHAT IS IT? The organization represents 162 countries and has published over 19,500 international standards. They meet on a regular basis to improve upon existing standards and to develop new ones. Businesses are not certified by the ISO; they are certified by a third party organization. ISO is about certifications and maintaining standards as these must be renewed on a regular basis. HOW CAN ISO HELP A BUSINESS? Standards have their own benefits across industries, but some benefits include: Widened CD market potential Higher efficiency/ money savings Improve customer service and customer satisfaction ratings Having an ISO certification is proof of a high-quality manufacturer. CERTIFICATION REQUIREMENTS Vary based on the standard a business wants to certify in. Varies based on the certification body COST OF CERTIFICATION and the selected certification. ISO CERTIFICATIONS ISO 9000-1 ISO 26000 QUALITY MANAGEMENT SOCIAL RESPONSIBILITY Provides guidance and tools to ensure products and services consistently meet customer's requirements, and that quality is consistently improved. Provides guidance to help businesses operate in a socially responsible way to contribute to the health of society. ISO 14000 ENVIRONMENTAL MANAGEMENT ISO 22000 FOOD SAFETY MANAGEMENT Helps to ensure the food safety chain remains safe, as much of today's food supply crosses international boundaries. Provides tools to identify and control environmental impact while constantly improving environmental performance. ISO 27001 INFORMATION SECURITY Helps to manage security of assets, such as financial data, and personal employee data. CASE STUDY I ISO Certified in 2001 MIDLAKE PRODUCTS These areas IMPACT ON BUSINESS: were chosen for certification, as Customer satisfaction is the number one they are relevant for the manufacturing benefit - expectations are being met throughout the process, not in just one area of the business. business. Allows the company to bid on Audit the following larger projects. 7 PROCESSES: Allows Midlake to compete with larger manufacturers for bigger projects. MANAGEMENT PURCHASING PRODUCTION Significant improvement in quality ratings which translates into a much smaller percentage of orders having some sort of problem. SALES ENGINEERING Lower scrap rate means keeping down reworking costs and improves the process for future orders. QUALITY DOCUMENT CONTROL Fewer internal reworks mean that fewer jobs have to be taken out and reworked to develop corrective action, Followed all standards except ISO standard 7.3 which deals with design and development as it is not relevant for manufacturing. Improved efficiency in everything from sales to design, manufacturing and through to invoicing. The end goal for a manufacturer is to improve efficiency in all parts of their process, drive profitability and improve customer satisfaction. START END ERICIENC PROSITABILITY SANISFACTION THEY USED 7 SO STANDARDS AND WERE ABLE TO: Increase Increase Improve productivity efficiency Improve stability of customer satisfaction by having better quality processes Reduce processes. waste and scrap Six Sigma and APOP are two methods of attaining an ISO certification. Putting the management concepts of Six Sigma and APOP into practice can improve your business. ISO certification is validation of the success of both of these processes. SIX SIGMA CONCEPTS 60 Six Sigma and APQP are a means to achieving ISO certification, they are both methods of system management and implementation. Six Sigma is the most proven method to attaining an ISO certification. Provides tools to improve the capability of business processes. WHAT IS IT? FOCUSES ON THE FOLLOWING CORE PRINCIPLES: Focus on the Identify and understand how the work gets done. customer. Manage, improve and refine the process flow. Remove Non-Value-Added steps and waste. Manage by fact and reduce variation. Involve and equip the people in the process. Undertake improvement activity systematically. HOW CAN IT IMPROVE MANUFACTURING? Increase in 1 performance Improve profits >> Boost employee morale Reduce defect Improve quality of products or services Decrease process variation SIX SIGMA CONCEPT: One of the Six Sigma certifications is Black Belt. Someone with this certification has a complete understanding of the Six Sigma principles and philosophies. They should be leaders that understand team dynamics and can handle assigning roles and responsibilities to their team members. Having black belts on staff helps reinforce culture and gives solid data for processes rather than using guess work Implementing Six Sigma a semiconductor manufacturer dedicated to manufacturing circuit cartridges for inkjet printers significant improvements to their manufacturing CASE Six Sigma was used to find and eliminate the at a causes of the errors, STUDY defects and delays in business organization able to provide processes. At baseline, they had process: a 3.2% defect rate. Their goal was a 1.6% defect rate. At the start of the implementation, electrical failures After Six Sigma implementation, they had a 1.32% defect rate. accounted for 50% of all product defects. APQP WHAT IS IT? Advanced Product Quality Planning (APQP) is a management tool similar to Six Sigma. The goal of APQP is to identify and weed out problems on a project before it gets to the floor. Largely involves sales, pricing, billing, purchasing, engineering and production. A method that includes steps to ensure your products satisfy your customers. HOW CAN IT IMPROVE MANUFACTURING? Avoids quality Improves communication Keeps your team focused Lowers issues your costs Honda Manufacturing of Indiana decided to move the task of assembling the power steering return hose to an outside facility. The outside facility, Indiana Assemblies, LLC (IA) used a strict APQP process that enabled them to exceed Honda of Indiana's expectations. CASE STUDY Engineers used a Process Failure Mode and Effective Analysis (PFMEA) of the chosen assembly process to locate and prevent all build problems. PFMEA A fixture was designed to assemble the return hose Required quality checks were organized in a Product Quality Control Table (PQCT) and the APQP process was used to ensure the build assembly in a single cell. The location and orientation of hose clamps were controlled better than in the past. processes produced consistently high quality products. Sources: iso.org, asq.org, dummies.com, journals.sfu.ca, omnex.com, adaptivebms.com, indianaassemblies.com AMidlake ((0::