Tailoring your Quality Management System in a Competitive Marketplace Heather Driscoll Infor Presales Business Solutions Consultant

Transcription

3 Presentation Premise Manufacturing environment will continue to change rapidly Competition will be intense Radically new products and processes will emerge New management and labor practices will emerge Manufacturing will remain one of the principle means of creating wealth 3 Copyright 2007 Infor. All rights reserved.

4 Tailoring Quality Management Systems Tailoring a quality management system to the specific needs of your organization is easier said than done What helps this process? Quality system models Standards (ISO9001, AS9100, TS16949, QSR, ISO13485) Regulations And Experience 4 Copyright 2007 Infor. All rights reserved.

5 Customers Expectations Maximize the value relationships among quality, service and price We can have it all attitude among customers force flexible and adaptable manufacturing systems Basis of competing for their business creativity and innovation 5 Copyright 2007 Infor. All rights reserved.

6 Manufacturing Response to Customers Expectations Enhance communication and knowledge-sharing for rapid response to market forces Information and knowledge on all aspects of manufacturing must be instantly available in a form that can be used for decision making Global distribution of highly competitive production resources Skilled workforce is critical for maintaining flexibility and responsiveness Develop innovative process technologies that support change scope and scale of manufacturing Find the optimum position in a better-faster-cheaper competitive triangle Optimize responsiveness, quality and profitability of the system 6 Copyright 2007 Infor. All rights reserved.

7 Case Study Company Privately owned Fabricate complete engine tube assemblies 1 plant Objectives Increase on time delivery Administration cost reduction AS9100 certification Real-time visibility Challenges All manual process Complex aircraft industry requirements No Quality system in place Need Lot Traceability Solution Infor Visual Quality Results Live in 6 months No addition to IT staff AS9100 certified Benefits Productivity increase 10% Decrease in Admin Costs 15% Increase On Time Delivery 25% ROI under 1 year 7 Copyright 2007 Infor. All rights reserved.

9 Infor Visual Quality Management (VQM) What is it? A highly integrated quality information system that lets quality management and business performance be managed as strategic issues One stop shopping for an e-qa system with the ability to grow our systems as our business needs grow. Our customers appreciate the new quality system because it allows the company to respond faster to their questions and requests. 9 Copyright 2007 Infor. All rights reserved.

10 A Proven Solution 10+ years of development and refinement Over 600 installs, both domestic and international Designed to meet various industries Quality needs Designed with ERP and MES system interfaces in mind Better yet, VQ is built on QA systems that have been in the manufacturing sector for years and supports our ISO initiatives. 10 Copyright 2007 Infor. All rights reserved.

12 Benefits of Visual Quality Management (VQM) Sixteen fully integrated modules Built around your business process Works in parallel with ERP systems Covers all areas of quality management: Quality Control (SPC, PDM, Inspection, etc.) Quality Assurance (Documentation, Process Mgmt.) Supports ISO9001, AS9100, TS16949, etc. efforts (Across the system) Finance (Cost of Quality) Management (Advanced Reporting, Audits, etc.) Since all the data collected is in electronic form the ease by which trend analysis is done is a huge benefit. It answers the question: From a quality perspective, what should we be focusing on? 12 Copyright 2007 Infor. All rights reserved.

13 Benefits of Visual Quality Management (VQM) cont d Groupware / Collaboration is built-in Direct activation and functionality Data sharing across modules & functions Real-time To Do Lists for each user Automatic scheduling and event management Build and manage teams, groups, etc. Collaborate between employees, supplier representatives, and customers Replaced 5 isolated quality system databases with one. Information is more accessible and more accurate, to the benefit of all quality-related processes. The new system gives people a single source for data, which has really improved the information flow within our company. That, in turn, makes many processes more efficient. 13 Copyright 2007 Infor. All rights reserved.

14 Benefits of Visual Quality Management (VQM) cont d Advanced reporting & EIS functions Numerous standard reports and tools 32-bit reports / SQL-compliant data Custom reports can draw data from both systems Features available across the system: Cost of Quality and Trend Analysis Object link or embed Manage quality across multiple plants Assign tasks/people/deadlines (To Dos) 14 Copyright 2007 Infor. All rights reserved.

16 Infor VISUAL Quality Management COQ Cost Of Quality Supplier Management Document Management Inspect Data Collection Product Documentation SPC Customer Management Process Management NCM Nonconformance Management Preventive Maintenance Employee Management PCA Preventive & Corrective Action Calibration Management APQP Advanced Product Quality Planning FMEAs Control Plans Quality Plans PPAP Task and Team Management Reports Project Control Production Part Approval Process Audit Management 16 Copyright 2007 Infor. All rights reserved.

17 Customer Management Customer list Unlimited number of entries Complaints, questions, RFQ s, suggestions Contract reviews Customer survey generator/manager Customer Management Our customers appreciate the new quality system because it allows the company to respond faster to their questions and requests for documents. 17 Copyright 2007 Infor. All rights reserved.

18 Supplier Management Supplier inventory Unlimited number of entries Approved supplier list Supplier survey generator/management tool Supplier Management Manage feedback, suggestions, complaints, RFQ s Allows documentation and automation of supplier ratings process Ability to capture receiving data (actual review as well as receipt of necessary documents) promptly and with reduced paperwork. 18 Copyright 2007 Infor. All rights reserved.

19 Employee Management Employee profiles Skills, education, certifications Job descriptions, surveys and performance reviews Training records and course scheduling Employee contact log Suggestions, peer reviews, attendance, etc Project Teams Meeting agendas and minutes Action items with responsibilities & due dates Employee Management Improved training record keeping for employees 19 Copyright 2007 Infor. All rights reserved.

20 Document Management Setup and Administration Master list of documents Approval and distribution lists Original documentation location Utilize existing document with link Indexing and Management On-line company dictionary Revision, Notification, and Distribution Check Out/ Check In Schedule and record document Audits Document Management 20 Copyright 2007 Infor. All rights reserved.

21 Product Data Documentation Master list of part documents Product Manage change requests Documentation Schedule and record document audits Inventory all products and characteristics By customer or supplier On-line inspection and test instructions Basis for inspection plans and control plans FMEA s (Potential Failure Mode and Effects Analysis) Understanding critical or key characteristics and knowing where to sample vs. 100% inspect. 21 Copyright 2007 Infor. All rights reserved.

22 Process Management Define inputs/outputs Process Customer focused Management PROCESS - part number independent Based on IPM methodology (KIV/KOV) Three level modeling and documentation Area, activity and key element(s) or critical characteristic(s) Manage change requests We created 18 Product families in Process and thus replaced monitoring and managing 5000 parts. 22 Copyright 2007 Infor. All rights reserved.

23 Preventive Maintenance Inventory of all capital equipment Handle 1-n components Preventive maintenance scheduling by Calendar, Usage or Both Reactive maintenance documentation Maintenance tracking - parts/ labor hours Spare parts inventory Preventive Maintenance 23 Copyright 2007 Infor. All rights reserved.

24 Calibration Management Inventory of all measuring equipment Calibration On-line calibration instructions Management Schedule & record calibrations and gage studies Allow for multiple characteristics per device Graph calibration results - interval analysis Device check in / check out Software keeps records about all calibrated devices. Not only is it impossible for devices to fall through the cracks, the new approach has eliminated a lot of document handling. We were planning on hiring one more person in the calibration lab to keep up with our growth, but that is no longer necessary. 24 Copyright 2007 Infor. All rights reserved.

25 Inspection Inspect Data Collection Linked to specs in PDM and Process management On-line viewing work instructions and blueprints On-line data collection for receiving, in-process and outgoing final audit Linked to Nonconformance Management Cp/Cpk, PPM and other reporting by gauge, machine, operator, supplier, operation, part #/characteristic, time period, serial number, etc. Parts specific controls plans SPC charting via collected data from Product and Process characteristics. We have learned first hand, by controlling our data, we continue to control our costs. 25 Copyright 2007 Infor. All rights reserved.

27 Nonconformance Management Single system to track all nonconformances Internal issues (part specific and system issues) Customer complaints, returns and warranty Supplier issues Can be entered manually or automatically posted from product and process test results Tracking by defect type, vendor, part number, program, cause, plant/division, etc Dispositions (multiple) and Approvals Verification Linked to associated Corrective and preventive actions Maintain audit trail NCM Nonconformance Management 27 Copyright 2007 Infor. All rights reserved.

28 Nonconformance Management NCM Nonconformance Management The software s use of pre-established values for specific data fields has improved the uniformity of nonconformance reporting. These NCM reports, now digital, are stored on the server and available to those who need them from their PCs. Access is immediate. This alone has reduced cycle time for handling NCMs from weeks to minutes. The improvements in reaction time and cycle time have been phenomenal. In addition, two people previously dedicated to filing NCM forms have been reassigned to other work. 28 Copyright 2007 Infor. All rights reserved.

29 Preventive and Corrective Action PCA Preventive & Corrective Action Inventory of all preventive & corrective actions Generated internally, by the customer or issued to Suppliers Manage different types of corrective actions Identify by part #, supplier, NCMs, etc. Assign employees and due dates Record-keep all related meetings and action items Assure effectiveness through scheduled follow-ups Automatic re-generation of failed corrective actions Maintain audit trail Project Control 29 Copyright 2007 Infor. All rights reserved.

30 PPAP Understand yields before full production begins Contains all Elements of PPAP (Production Part Approval Process) or trial runs Provides management of each PPAP element Complete change control and traceability Each element pulls data from other VISUAL Quality modules, or you can use links to existing documentation PPAP Production Part Approval Process 30 Copyright 2007 Infor. All rights reserved.

31 APQP Structured around the 5 step APQP (Advanced Product Quality Planning) process Pulls information from other VQ quality systems like PPAP system (real-time information) Full status tracking and management of all elements/checklists of APQP APQP Advanced Product Quality Planning 31 Copyright 2007 Infor. All rights reserved.

32 Audit Management Auditing structured around your system Generation of checklists/questions or link to associated audit documents Generation of audit schedules with copy features for generating 3 to 5 year plans Documentation of observations, findings, nonconformance, and corrective actions Audit Management 32 Copyright 2007 Infor. All rights reserved.

33 Cost of Quality Automatic posting from other modules Categorize appraisal, preventive, internal and external failure costs into an unlimited number of categories Analyze against unlimited number of measurement bases Provides true activity based quality costing COQ Cost Of Quality 33 Copyright 2007 Infor. All rights reserved.

36 VISUAL Quality s Value to your Organization The Infor Visual Quality Management provides a solution for success including the tools to: Tailor your Quality System for optimal competitive position Standardize your Processes Collaborate with your suppliers, customers, partners Secure senior executive support to drive system adoption and compliance Implement Early Warning Programs for defective material and/or delivery issues 36 Copyright 2007 Infor. All rights reserved.

37 Summary As you can see, the Infor Visual Quality solution provides many opportunities to increase efficiency and reduce nonconformances, thereby decreasing cost of goods sold and increasing earnings. As stated earlier, tailoring a quality management system to the specific needs of your organization is easier said than done. Utilizing one integrated quality assurance system begins the journey of moving from isolated islands of systems information to one comprehensive solution. We provide the people and the tool to help you achieve and maintain your specific goals. Thank you for your time and participation! 37 Copyright 2007 Infor. All rights reserved.