presented by: brian harvey quality manager – clamonta ltd a small business perspective & 9103...
TRANSCRIPT
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presented by:
Brian Harvey Quality Manager – Clamonta Ltd
asmall
businessperspective &
9103presented to:
IAQG
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agenda
• morning presentation– how a small business implemented
9103
• afternoon break out session– 9102 FAI process improvement
software
presented by:
Brian Harvey
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located: Nuneaton, Warwickshire, UKemployees: 45sales: £4.25 millionestablished: 1960manufactures: components & assembliesapprovals: 9100 & NADCAP
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continuous improvement
strategy
processimprovement
chartingkaizen EFQM5s
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9103 barriers
1. middle management2. cost/benefit3. communication4. training5. data collection method6. product type
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?
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process improvement charts:individuals X
UCLx
LCLx
1. measurement data
2. equipment3. batch/job
number4. date & time5. location
1. text message or e-mail to process owner
2. cause & corrective action from chart ownerdiscovering the
truth about our processes
andtraining our people at the
same time
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Real Time Process Improvement
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facilities layout
office
turncell
millcell
grindcell
ndt
lockplatecell
heattreat
runnersrepeater& strangers
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repeater & strangers
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• 300 parts/ month
• batch sizes 1 to 24 off
• repeat 1 to 5 years
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January 2003
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September 2003
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repeaters & strangers results
failure
appraisal
prevention
failure
appraisal
prevention
qualitycosts
before after
1 person running 2 CNC lathes3 month trial40 parts numbers4000+ measurements
4 non-conforming parts
WITH
4 people running 8 CNC lathesaverage 40 part numbers each
200+ non-conforming parts
WITHOUT
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runners
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• 55 part numbers
• 65000 parts / year
• batch sizes 100+
• repeat 1 to 4 months
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Cpk improvements
• milling fixtures problems < 1.33 Cpk
• our team solved that problem• now >1.66 Cpk
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(parts per million)
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runners ‘cell’ results in <5 years
• <½ resource• 35% more product• in-process inspection only • zero delivered non-conformance• <£4K internal scrap (£950K
turnover)
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9103 savings
1. reduced non-conformance2. improved root cause problem
resolution3. increased efficiency4. improved flow
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Clamonta LtdWhitacre Road
NuneatonWarwickshire
CV11 6BXUnited Kingdom
Tel:+44 (0) 24 76382447 / 76370307Fax:+44 (0) 24 [email protected]
www.clamonta.co.uk
thank youhand overto Delta -
Dave Wentworth