presented by:

Brian Harvey Quality Manager – Clamonta Ltd

asmall

businessperspective &

9103presented to:

IAQG

agenda

• morning presentation– how a small business implemented

9103

• afternoon break out session– 9102 FAI process improvement

software

presented by:

Brian Harvey

located: Nuneaton, Warwickshire, UKemployees: 45sales: £4.25 millionestablished: 1960manufactures: components & assembliesapprovals: 9100 & NADCAP

continuous improvement

strategy

processimprovement

chartingkaizen EFQM5s

9103 barriers

1. middle management2. cost/benefit3. communication4. training5. data collection method6. product type

?

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

Real Time Process Improvement

facilities layout

office

turncell

millcell

grindcell

ndt

lockplatecell

heattreat

runnersrepeater& strangers

repeater & strangers

• 300 parts/ month

• batch sizes 1 to 24 off

• repeat 1 to 5 years

January 2003

September 2003

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

runners

• 55 part numbers

• 65000 parts / year

• batch sizes 100+

• repeat 1 to 4 months

Cpk improvements

• milling fixtures problems < 1.33 Cpk

• our team solved that problem• now >1.66 Cpk

(parts per million)

runners ‘cell’ results in <5 years

• <½ resource• 35% more product• in-process inspection only • zero delivered non-conformance• <£4K internal scrap (£950K

turnover)

9103 savings

1. reduced non-conformance2. improved root cause problem

resolution3. increased efficiency4. improved flow

Clamonta LtdWhitacre Road

NuneatonWarwickshire

CV11 6BXUnited Kingdom

Tel:+44 (0) 24 76382447 / 76370307Fax:+44 (0) 24 76381312brian.harvey@clamonta.co.uk

www.clamonta.co.uk

thank youhand overto Delta -

Dave Wentworth