Incoming Inspection and In-Process Quality in Costpoint Manufacturing Execution

Billy Shumate, Principal Consultant, DeltekTerry Howell, Principal Consultant, DeltekGC-355

Agenda

SUPPLY CHAIN QUALITY ASSURANCE

OVERVIEW

QUALITY REQUIREMENTS AND INSPECTION PLANNING

SUPPLIER QUALITY EXECUTION

SUPPLIER QUALITY CORRECTION

QUALITY MANAGEMENT SYSTEM

OVERVIEW

MANUFACTURING PROCESS PLANNING

MANUFACTURING PROCESS EXECUTION

MANUFACTURING PROCESS QUALITY

CORRECTIVE ACTION

Supply Chain Quality AssuranceOverview

MES’s Supplier Quality Assurance system enables a systematic and dynamic approach to managing supplier quality.

Provides a complete paperless system for defining, managing, communicating, and verifying product specifications and requirements.

Offers a comprehensive quality-management solution for all discrete, complex manufacturers.

Quality requirements & Inspection Planning

The Inspection Planning provides tools to manage the definition of inspection and verification plans.

Ensures compliance to specifications mandated by engineering requirements, contracts, and industry process standards.

Supplies a central location for the authoring and maintenance of inspection requirements for product-key characteristics including handling, labeling and packaging.

Characteristic-measurement requirements include upper and lower spec limits, and sampling rules.

Quality requirements & Inspection Planning (cont)

Inspection and verification specifications can be set at different levels for easier change management:

Standard Requirement Group Part Number Specific Supplier/Part Number Specific

Each applicable level is added to form an Inspection Order

Each measurement or observation characteristic is assigned a sampling plan that determines the frequency and sample size for each inspection. For example:

Characteristics considered critical may have 100 percent of all parts sampled and inspected.

Minor characteristics may have a smaller percentage of parts sampled and inspected.

Based on recorded failure history, severity switching rules can include switching logic to automatically switch to tighter or more relaxed sampling plans.

Inspection Items (Characteristics) without any issues will gradually receive less attention, while trouble spots will receive more scrutiny.

Inspection Item Class

All Inspection Items have an assigned Class.

Each Class has an associated Acceptance Quality Level (AQL).

The AQL values are used to determine the Inspection Item sample size.

CLASS AQL

Critical 0 %

Major 1 %

Minor 4%

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Sampling Rules

The Sampling Rules define the Sample Plan and Severity Switching

Sampling Plans

The Sample Sizes logic is included in the Sampling Plans

Switching Logic

The Switching Logic changes the Sampling Rule Type based on the inspection results.

For example: The Sampling Rule Type may change from Normal to Full Inspection.

The Switching Logic automatically adjusts the AQL based on the performance of the Inspection Item for a Supplier/Part.

Inspection Plans

Receiving Inspection

Over Inspection

Special Inspection

Inspection

Steps

Receiving Checklist

Pre-InspectionChecklist

Check-List

Steps

Inspection Plan

Inspection Steps

Inspection Steps are place holders for inspection items defined in the inspection definition.

Inspection steps names are user defined.

Checklist Steps

Boolean Yes/No questions.

Documentation gathering through attachments.

Checklist Workflow

Allows workflow through the checklist process based upon the question results.

Inspection Definitions

Container of all the inspection items required for inspection.

Can be created at three different levels - part, supplier part, or requirement group.

The requirement group can be for anything: a process requirement, a part family, a commodity code or even a government requirement.

Revision controlled and the system will default to the latest, completed revision during inspection plan creation.

Can contain attachments such as drawings, specifications, and multimedia.

Inspection Definitions

Inspection Item

Contains 4 elements of information

Inspection Item Steps

Steps are assigned to inspection items.

Steps are inspection points within an inspection process. Inspection steps are used to map inspection items to the inspection plan.

Inspection items associated to an inspection step appear in the inspection order.

Subordinates

Inspection Items can be identified as Master or Subordinate.

If a Master Inspection Item is rejected then all of the Subordinate Inspection Items become mandatory.

If the Master Inspection Item passes then the Subordinate Inspection Items become optional.

Requirement Groups

Consist of a grouping of inspection items that can be applied to parts or suppliers.

Process requirement, part family, and commodity code or government requirement.

Allows the attachment of documents required for a requirement group. An example would be: OHSA or ISO specifications.

 

When an inspection order is created for an item in the group the corresponding inspection items from the requirements group will also be included.

When an inspection order is created for that supplier the corresponding inspection items from the group will also be included.

Inspection Planning to Execution

Dispatch List

When an inspector logs on, all of the relevant open purchase orders appear in the inspector-associated dispatch list.

Inspection Orders – Execution

All requirements are viewable by the inspector, including specification limits, criteria and inspection method data.

First Article Inspection (cont)

When purchase orders contain open FAI or FAI delta requirements, the system flags the next inspection order accordingly.

Ensures that all of the requirements for a FAI are compliant with AS9102 requirements.

FAI requirements must be completed before any units can be accepted.

Supplier Quality Correction

 Processes provide mechanisms for analyzing quality performance.

Responding to discrepancies discovered during inspection execution.

Tracking continuous process improvement efforts as Corrective Actions with suppliers.

Respond to discrepancies discovered during inspection execution.

Analyze quality performance.

Track continuous process-improvement efforts with suppliers.

Discrepancy Flow

Creating a Discrepancy

Creating a Discrepancy

Discrepancies (cont)

The disposition, review and approval workflow is configured to handle complex routing requirements for different types of discrepancies.

Discrepancies are classified based

on defect, symptom, and cause types.

A disposition can include instructions

to rework, repair, or scrap.

Quality Holds

Holds prevent any further work from being done on an inspection order.

Visibility of holds is never lost throughout the process.

Supplier Quality Analysis Tools

Supplier performance is tracked consistently

Supplier Quality Analysis Tools

Supplier performance is tracked consistently

Quality Management System Overview

Fully manages all aspects of quality – from discovering and tracking defects to identifying and issuing the appropriate corrective actions.

Identifies quality issues early in the process, reduces scrap and rework.

Provides complete visibility into quality processes, accumulating the complete product genealogy for each unit in real time.

Provides a full audit trail of the work process.

By collecting these careful records, meets the strictest process management and integrity requirements for multiple industries.

Product and Process Control

Provides operators with easy-to-follow, enhanced work instructions

Work instructions can be as simple as text or complex, including attachments and multimedia.

Ensures quality standards by collecting electronic signatures, and incorporating inspection verification and statistical process control.

Stores as-built product and device history on each unit by serial or lot number, including:

Work instructions Data collection Buyoff signatures Discrepancies Repairs Materials Components and subassemblies used

Inspection Instructions

Inspection instructions are incorporated into Work Plans, prescribe how to verify that each product is built or serviced to engineering specifications.

Inspection Instructions Include:

Inspection and test operations.

Data collection requirements with control limits.

Certified buyoff stamp requirements.

Data Collections

Embedded in instruction text blocks.

Two types are used:

Parameter - Record measurements and notations taken during work order execution, such as time, temperature, pressure, etc.

Calculated - Automatically execute formulas using values entered into parameter data collections.

Work Instructions

Work Order Processing

Data Collection and Buy-Offs

Work Orders –Creating a discrepancy

Initiating a Discrepancy from a Buyoff.

One of the most common ways to initiate a discrepancy.

Normally discovered on the shop floor and the Quality inspector or Shop Floor user will reject the buyoff and create a discrepancy.

 

Work Orders –Creating a discrepancy

Initiating a Discrepancy from a Work Order.

Method used if there is not a buyoff in an operation where you want to initiate a discrepancy, or if a buyoff is not open at the time the discrepancy is found.

 

Types of Dispositions

Use As Is: The part is OK to use as it is.

Scrap: Part cannot be used.

Return: The part cannot be used and is to be returned to its vendor.

Rework: The part can be fixed and used.

Repair: Can be repaired and reused.

Replace Unit: Unit is scrapped and replaced by a new unit.

Determines how the part will be processed (disposition instructions)

Disposition instructions allowed for Rework and Repair

Disposition Instructions

Append to Operation: Adds an instruction to a specific operation/steps in the original work order.

Alter Existing Instructions: Opens the original work order and puts it into alteration.

New Work Order: A new work order is created to process the discrepancy

Existing Work Order:

An existing work order for the

same part number that is put

into alteration.

When approved new WO instructions released to the shop floor.

Rework and repair operations processed the same as planned work

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Authorize All Open WO’s for Discrepancy Serial/Lot

Authorize All Open WO’s for Higher Level Units

Authorize a Single Open WO

Liens

Quality Metrics

Real-time reports and charts to view quality metrics, and drill down into problem areas for more details.

Real-time reporting feature measures: Defects per Million Opportunities (DPMO) Defective Parts Per Million (DPPM) Six-Sigma and Defect Normalization.

Continuous visibility of DPPM by Supplier/Part

Real-time SPC indication of Out-Of-Control data collection measurements

Quality Metrics (SPC “U” Chart)

At the time a nonconformance is initiated, real time SPC data analysis is performed.

Trending Charts

We can be proactive and initiate CA manually where we see biggest opportunities

Continuous Improvement (Kaizen)

46 ©2012 Deltek, Inc. All Rights Reserved

We can be proactive and initiate CA manually where we see biggest opportunities

Continuous Improvement (Kaizen)

Quality Historical Charts

Processing CA Requests

Or Request CA from Discrepancies when action or recurrence are obvious

Link to Existing Or Create New CA

It is ok to Deny CA Request…Not every Discrepancy calls for CA

CA is configurable to support different processes

8D Process for Root-Cause Corrective Action

Form the Team

Everyone sees the CA on their task list.

Easy to know who is working on what.

Describe the Problem

Time to document the Problem Description

As we investigate… we come back and can add more details.

Affected Resources

Identify all affected/related Parts, Tools, Machines, Suppliers, Customers

When first observed, frequency, etc.

Attach Illustrations / Documents

We can also attach pictures or documentationWe can also attach pictures or documentation

Contain the Problem

Until Corrective Action completed, cannot ship product unless it has been verified not to have a problem.

Containment Actions

On Supplier side… Containment Holds are automatically placed and prevent

shipment without special authorization until CA completed

On Inventory side… We can create Work Orders to Inspect inventory in stock

On Operations side… We can add alerts where components are installed to check

for condition until CA is completed.

On the Customer side… With integration to ERP, we can identify which units went to

which customers and might need notification.

Identify Root-Cause

The team should document Investigation as they go (not just at the end)

Investigation Notes

Environment Has anything changed in the last 2‐3 weeks? Nothing

apparent.

People Any new employees involved? No Has work rate changed recently? No

Methods Are methods described properly? Usual for this type of work Were prescribed methods followed? Yes

Machines…

Investigation Notes

Machines Is equipment showing signs of aging wear and tear? Was equipment properly calibrated? Not sure Why is this a suspect cause? Because there is no record of what gauge was used Investigated Tool Calibration in respective department Found that some of the tools at the shop floor are out of

calibration

Configure Templates to automatically attach to each CA

Add common issue areas to templates to promote thorough investigation

Common Issue Templates

Document the results of the Investigation

Attach Documents

Attached meeting records

Supporting Documentation

Documented each Action Item recommended as part of the investigation.

Identify responsible department and manager. Manager must acknowledge.

Action Item Closure

Identify who will verify Implementation for each Action Item.

Action Item Verification

Once Effectiveness is verified, we can make the new processes permanent.

Verify Effectiveness

Effectiveness Verification

The CA team plans the timing and criteria for the effectiveness verification.

They can associate files that contain verification instructions.

Finally a Corrective Action is deemed effective or non-effective

We can create New CA’s for Preventive Actions to prevent similar problems.

Easily jump between linked CA’s.

Permanent Correction

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Corrective Action Tasks

Prioritize CA’s by Risk Score.

Evidence of compliance for AS9100, Risk Management

Risk Score to prioritize CAs

Risk-Score = (Likelihood-Rating-Score) x (Severity-Rating-Score) x (Detectability-Rating-Score)

Severity is based on a scale from Tolerable to Intolerable based on impact to Safety, Product Quality/Mission Assurance, and Schedule

Likelihood-Rating-Desc

Likelihood-Rating-Score Severity-Rating-Desc

Severity-Rating-Score Detectability-Rating-Desc

Detectability-Rating-Score

Every Unit 5Untolerable - no work around and high impact or safety issue 5 Integrated Testing Required 5

Every Day 4 Painful level of rework or work around 4 Destructive Testing Required 4

Every 1-2 Weeks 3Significant impact to schedule/mission/cost 3 Unit Testing Required 3

Every 1-2 Months 2 Tolerable level of rework 2 Measurement Required 2Rare 1 Tolerable workaround 1 Visual Inspection 1

The CA list prioritized by Risk Score can be used as part of evidence of compliance with AS9100 Clause 7.1.2. Risk Management.

Corrective and Preventive Action

Closed-loop corrective and preventive action process manages requests, action items and verifications.

Can be initiated from discrepancies or corrective action requests.

Several requests can be linked to a single corrective action.

Requests are created to track internally or externally initiated issues, such as recurring defects or customer satisfaction concerns.

Each corrective action is coordinated by a facilitator, who follows up on action items until a resolution is reached.

Includes a root-cause corrective action feature that determines the cause of a nonconformance and implements a corrective action to prevent it from reoccurring.

To ensure non-conformances and corrective actions are properly identified, the 8D problem solving process is used.

Thank You!

billyshumate@deltek.com terryhowell@deltek.com

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