Figure 1
Business Process Improvement Results Shared by Current Users
Solumina Supplier Quality Management System enables a new systematic and dynamic approach to managing quality with suppliers.
Solumina provides a complete paperless system for defining, managing, communicating and verifying product specifications and requirements with suppliers. Quality can be managed at the supplier efficiently down to the characteristic level with processes that parallel the internal processes.
Quality Engineers plan product and inspection specifications, which include product characteristics, tolerances, and rules for sampling, oversight and audits. First Article Inspection (FAI) requirements are specified in compliance with FAA and AS9102 guidelines.
SOLUMINA SQA SOLUTIONS
1
Minimize Inventory in Receiving Inspection
Solumina’s collaborative quality approach enables
more inspections to be performed at the supplier
site via the web instead of inspecting after receiv-
ing. Inventory items in receiving inspection are
minimized. Products can ship directly from the sup-
plier to work-in-process at the plant based on the
supplier’s quality rating for the specific part and the
rules established by quality managers.
Minimize the Need for Third-Party Contract Inspection
Solumina provides the ability to remotely review
and approve source inspection data including mea-
surements, check lists and certifications. Inspec-
tions and audits can be performed at the supplier
site by customer, supplier, or third party contrac-
tors as specified by the quality manager for each
supplier and part. The application provides a sys-
tematic way to manage the oversight of source in-
spections performed by suppliers in order to mini-
mize the need for third party contract inspection at
the supplier’s facility.
Quality issues are identified earlier at the supplier
site and corrected before shipment of goods is au-
thorized. Quality issues that escape and are found
downstream during the assembly process, have a
greater impact on the supplier’s metrics, and trig-
ger containment and Corrective Action.
Improve SupplierPerformance
Reduce Cycle Time forSupplier Issue Resolution
Reduce Inventory inReceiving Inspection
Reduce Admin andContract Inspectors
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2
Eliminate Manual Management Tasks
Receiving inspection, source inspection and suppli-
ers can perform all necessary transactions via the
web. But Solumina’s Supplier Quality Assurance
system does more than deliver forms to suppliers
via a web portal. The system dynamically generates
inspection and audit requirements for each PO line
item based on the most recent history for the spe-
cific part and for the specific supplier.
As supplier quality increases, the system relaxes
oversight requirements based on pre-established
inspection oversight rules for different types of
parts. Conversely, the system tightens inspections
and oversight as defects are found either at the sup-
plier location, or downstream during the assembly
process. The automation of oversight rules elimi-
nates the need to manually manage intervention
and ensures that all suppliers are managed consis-
tently.
Users are stepped through check lists and data col-
lections, which can be configured to branch based
on user answers. In-process recorded measure-
ments and observations trigger instant feedback on
out-of-tolerance and out-of-control conditions.
Reduce Cycle Time to Resolve Supplier Issues
Users can document Discrepancies at the source, at
Receiving, or when an escape is found on the shop
floor. Solumina includes a completely integrated
discrepancy documentation, classification, disposi-
tion, and Corrective Action system.
Every manager, engineer and production mechanic
strives for zero defects, but the reality is that discrep-
ancies and defects happen. Real-time communica-
tion between suppliers and buyers make it possible
to react quickly to disposition issues when they arise
on the shop floor. The Solumina system continuous-
ly monitors quality based on inspection results and
provides a methodology to continuously improve
quality. When repeat escapes are found, the system
initiates containment and Corrective Actions.
Improve Supplier Performance
Supplier performance management is critical to
controlling production costs, reducing variance,
and protecting the quality standards associated
with the brand name.
Solumina provides the capability to query real-time
supplier status, constraints, and history records
for all processes and activities related to product
quality and production history. Graphs and reports
include inspections, supplier ratings, DPPM, and
discrepancies.
Solumina enables a self-managed quality path for
suppliers, which increases awareness and owner-
ship of process strengths and weaknesses. The col-
laborative quality system provides the supplier with
an easy to use tool to help diagnose which processes
need the most attention.
Solumina Supplier Quality Assurance includes these features:
• Configuration-managed product characteristics, inspection re-quirements, and rules for sampling, oversight and audit
• Generative Inspection Planning
• Sampling and oversight plans with rules for automatic sample size adjustments based on each supplier’s part history
• Records for all processes and activities related to product quality
• Real-time communication among suppliers, buyers and quality managers
• Two-way communication for inspection results, supplier rating, DPPM graphs, discrepancies and corrective action
• Dynamic inspection requirements for each Purchase Order based on supplier performance
• Online Verifications and Characteristic Data Collection
• Discrepancy report, Issue/Defect Containment Holds and Correc-tive Action Requests
• Quality analysis tools that provide a self-managed path for suppliers
• Strict rules for compliances with AS9102 First Article Inspection requirements
• Gradual transition of more component inspections to the supplier
Figure 2
Verifications and Characteristics Tied to Requirement, Part or Supplier Part
Solumina’s Supplier Quality Assurance functionality can be used by itself or coupled with other Solumina quality management functions used to manage internal production operations. The Solumina suite of software solutions provides a comprehensive quality management solution for your organization.
SOLUMINA SQA FEATURES
3
Product Specifications
Solumina provides organization and management
tools to develop a library of product specifications,
process specifications, inspection requirements,
and rules for sampling, oversight and audit. These
dynamic inspection and verification requirements
are dispatched over the web to the supplier site for
each purchase order line item. All inspection data
collection is recorded in Solumina and can be used
to determine which areas need to be enhanced, and
which suppliers require additional oversight or
Corrective Action.
Inspection Planning
Solumina provides a central location for the author-
ing and maintenance of inspection requirements
for product key characteristics and verifications
for process requirements including handling, la-
beling and packaging. Characteristic measurement
requirements include upper and lower spec limits
and sampling rules. Inspection and verification
specifications can be set at hierarchal levels with
the following override capabilities:
• Standard Requirement Group
• Part Family Specific
• Part Number Specific
• Supplier/Part Number Specific
Sampling Plans
Each measurement or observation characteristic
is assigned a sampling plan that determines the
frequency and sample size for each inspection.
For example, characteristics that are considered
critical can cause 100% of all associated parts to be
sampled and inspected. Characteristics considered
minor can cause a smaller percentage of parts to be
sampled and inspected.
Each sampling plan can optionally include switch-
ing logic that defines rules for automatically switch-
ing to a tighter or more relaxed sampling plan based
on recorded failure history. Inspection items or
characteristics with no issues gradually receive less
attention while trouble spots receive more scrutiny.
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Figure 3
Verification Requirements at the Source,
Receiving or Both
Figure 4
Supplier Quality Performance Metrics
Include DPPM
4
Process Control
The process control features assure that all verifi-
cations are performed and documented in the pre-
scribed order, that inspectors have the proper cer-
tifications to perform certain inspections and data
collections, and that the latest characteristic mea-
surement and sampling requirements are applied
including the type of gauge required.
Purchase Order Information
When an inspector logs onto Solumina, all rel-
evant open purchase-order line items appear in a
dispatch list. On command, each purchase order
generates a corresponding Inspection Order whose
instructions are based on current characteristic, in-
spection, and sampling requirements. All require-
ments are in full view including specification limits,
criteria, and inspection method details.
Online Verification and Data Collection
The Inspection Order includes all characteristic
data collections that must be performed. The user
interface makes data entry easy by prompting the
inspector for each check list item, observation, and
measurement required. When inspectors log on to
the system, they quickly return to where they left off
in the Inspection Order.
Solumina lets the inspector know what data collec-
tions remain before the inspection can be complet-
ed. The system also alerts when entered values are
out of range.
Optimized Inspection and Audit Oversight
Certain suppliers will require more inspection over-
sight than others. Solumina randomly determines
which Inspection Orders will be selected for over-
inspection based on each supplier’s historical and
recent quality performance. The system ensures
that the over-inspection is performed by an Inspec-
tor different from the one performing the primary
inspection.
First Article Inspection
When Purchase Orders indicate that there is an
open First Article Inspection (FAI) or FAI Delta
requirement, Solumina ensures that the next In-
spection Order is flagged accordingly and contains
all the requirements for the FAI in full compliance
with AS9102 requirements. The FAI requirements
must be completed before any units can be shipped
to the buyer.
Figure 5
Supplier Portal for Two-Way Communication with Suppliers via the Web
5
Supplier Quality Analysis Tools
Supplier performance management is critical to
managing production costs, reducing variance, and
protecting the quality standards associated with
brand names. In Solumina, each supplier’s perfor-
mance is tracked consistently with full visibility of
all supplier-induced issues and defects found dur-
ing inspection at the source, or as an escape down-
stream in the manufacturing process. Solumina
displays quality performance metrics in easy-to-
read charts and reports that can drill down all the
way to the specific Purchaser Order and inspection.
Suppliers with a high defect or failure rate are high-
lighted.
Discrepancies
Discrepancy and defect reporting are fully integrat-
ed and initiated directly from an Inspection Order.
The inspector is required to initiate a Discrepancy
report if any of the characteristic data collections
are rejected or out of limits. Discrepancies are au-
tomatically routed to the appropriate personnel.
Discrepancies caused by a supplier will affect the
supplier’s performance rating.
The disposition, review and approval workflow is
configured to handle complex routing requirements
for different types of discrepancies. Communica-
tions further complement the process, document-
ing review and discussion threads.
Discrepancies and defects are classified by respon-
sible processes, defect types, symptom types and
cause types. Analysis of defect classifications pro-
vides the basis for needed Corrective Actions.
A unit’s disposition can include instructions to re-
work, repair or scrap the unit. A defective installed
component or subassembly can be fixed in place or
removed. The defect moves with the removed com-
ponent. The removal history stays with the assembly.
Benefits:
• Improved component parts quality
• Fewer quality escapes
• Least inventory in receiving inspection
• Minimum third party contract source inspection
• Lower sourcing and warranty administrative costs
• Reduced inspection and audit oversight cost
• Quicker issue disposition and corrective action
• Increased supplier ownership of process strengths and weaknesses
6
Figure 6
Defect Containment is Automatically Flagged
until Correction Action is Verified
Figure 7
Corrective Action Initiated from
Discrepancy Report
Quality Suspect and Defect Containment
Defect containment Holds prevent further ship-
ment of suspect parts without verified Corrective
Action, over inspection, or explicit approval. Alerts
are immediately placed on all affected Inspection
Orders. Visibility of Holds is never lost throughout
the process.
Solumina includes various types of Holds includ-
ing “red decal” Holds which identify an item that
is authorized to ship because an issue cannot be re-
solved at the supplier site. Corrective Action Holds
are also automatically placed on any Inspection Or-
der for parts that have pending Corrective Actions
with the supplier. The Hold can be lifted by the
buyer or quality manager to approve shipping even
though Corrective Action is still pending.
Corrective and Preventive Action
Solumina’s closed-loop Corrective and Preventive
Action (CAPA) process manages investigation, ac-
tion items and verifications. Each Corrective Action
is a project coordinated by a facilitator responsible
for following up on investigation and action items
until there is an agreement and commitment on
resolutions.
Corrective Action can be requested from either dis-
crepancies or Corrective Action Requests. Correc-
tive Action Requests are created to track process
improvement suggestions or issues like recurring
defects, or customer satisfaction concerns. Several
requests can be linked to a single Corrective Action.
The Corrective Action tracks investigation, root-
cause analysis, and resolution commitments. Ac-
tion items are routed according to the responsibility
identified. The root-cause analysis process can be
escalated according to the severity of the issue and
more participants can be added to the investigation
team from multiple disciplines.
The Corrective Action process is not complete until
implementation is verified and proven effective. So-
lumina allows scheduling of implementation veri-
fication tasks according to the commitment dates.
Containment processes are tied to the Corrective
Action until subsequent effectiveness verification
is recorded to verify the success of the prescribed
solutions.
Copyright © 2013 iBASEt. All Rights Reserved.
Solumina is an Operations Process Management (OPM) software suite that manages work and quality processes for the manufacturing and MRO (Maintenance, Repair and Overhaul) of highly engineered products. Solumina functional modules include Process Planning (CAPP), Manufacturing Execution System (MES), Quality Management System (QMS, CAPA), Supplier Quality Assurance (SQA), and Maintenance, Repair and Overhaul (MRO) in one integrated system.
Solumina is uniquely designed to manage the product life cycle, beginning with product and process quality speci-fications into the supply chain, continuing with the manufacture of component parts, the assembly of product, and the aftermarket service of each product unit until retirement.
Solumina functional modules include:
• Solumina Operations Process Management for Manufacturing• Manufacturing Execution System• Quality Assurance System (QA, Discrepancies, CAPA)
• Solumina Operations Process Management for Maintenance, Repair and Overhaul• Maintenance Requirements Planning• Maintenance Task Planning• Maintenance Online Execution, Non-routine Execution
• Solumina Supplier Quality Assurance• Supplier Inspection Planning• Receiving and Source Inspection• Discrepancy Reporting and Corrective Actions
More papers and resources available for download at the Library section of our website: www.solumina.com.
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