Continual Improvement
Continual improvement is an ever running process in Quality. Understanding why processes created deviations is the bases for improvement.
The options
Plan-Do-Check-Act
Once the Strategic Quality Plan is setup, clearly communicated and agreed, it is time to roll out, monitor and improve. The most common process to use is the PDCA Cycle. Less known is the Define-Measure-Analyse-Improve-Control (DMAIC) Cycle based on the Six-Sigma approach. Both can be used and both have their "pro's and con's". Quality is an ongoing process which needs to run continuously, you are never finished.
We have many years of experience in this field and can advise you how to run the PDCA Cycle and successfully introduce the required quality level.
Failure Analysis
Why is the product Non-conform? Only when you know the root cause, you can improve your processes and products. The biggest mistake is jumping to conclusions. A failure analysis is like working on a murder case: you restrict access, mark the evidence and start to analyze where the defect came from. Once done correctly, it will be a valuable Lesson Learned. Failure Analysis and Six Sigma go hand-in-hand. A correctly run Analysis process will provide the Organization with very important lessons learned which can be used for future designs.
Let us advise you on how to run the process and find the real root cause.
Process Optimizations
Every minute that a process is not running as it should, it creates unnecessary cost. Optimizing processes is a combination of Risk Analysis, Personnel Training, Tool design and maintenance. But most of all collecting data, a lot of it. Setting up the right Key Performance Indicators is like choosing the right sensor to measure your personal health. The wrong one will not give you the data you need to define what to do next. Is the process running stable enough? Does the personnel know how to run the process? Are the right outputs monitored?
After spending hundreds of hours at production lines we have the experience to support in Process Optimizations. Let us advise you on how to get the most out of your Process.
Risk Analysis
As part of ISO 9001 you need to know the risks your company has when producing a product for your Customer. A good Risk Analysis is a blueprint for comparable products and can be used as guideline when designing a new Revision or evolution. Please don't make the same mistake twice. Are you sure the Risk Analysis was done with the right stakeholders? Are you sure they can be fully open to express their concerns? Have Lessons Learned been considered?
Let us advise you on how to do a Risk Analysis properly.