Quality Journey from Cost to Value
Tom Hines Dept. Manager - Ada Operations QA
Science Symposium and Expo 2015 October 21, 2015
A GLOBAL
LEADER
2014 global
annual sales of
USD $10.8
BILLION
Operates in more
than 100 countries
and territories
Hold more than
1,000 patents with
more than 700
patents pending
Offers one of the world's leading
business models for entrepreneurs
looking for more time, money and
flexibility.
21,000 Amway
employees
support more
than 3 million
distributors
The world’s #1
direct selling
business
(Direct Selling News Global 100)
More than 450
unique, high-
quality products
are manufactured
and distributed by
Amway
Quality Journey from Cost to Value
TEST
MEASURE
LEAN
DESIGN
ALIGN
Journey (n): 4. passage or progress from one stage to another
Amway Headquarters & Manufacturing Facility Ada, Michigan
Simple View of the Supply Chain
Incoming QC Ensure Quality Manage Risk Protect Facility Compliance Feedback Cost Time
Product QA Assure Quality Manage Risk Protect Consumers Compliance Cost Time
While the value of quality assurance processes and activities across the supply chain is well established, there still seems to be a wide spread questioning of the cost and time associated with it.
TEST
Key Progress
• Specification review & alignment
• Test method interpretation & optimization
• New technology - UPLC (ultra high pressure liquid chromatography) - Celsis (rapid micro detection) - XRF (x-ray fluorescence) - “Proofing” (video artwork & text verification) - LIMS system - “Smart” sample carts - “Live” screen displays
• Analyst training program
• ISO 17025 certification
• Sample vehicles
TESTING (n): 6. the process of identifying, detecting or confirming the presence of a constituent of a substance, or of determining the nature of a substance.
MEASURE
Key Learnings:
• Measure everything The Few Right Metrics
• New QA metrics: - Release Time (days)
- Operational Excellence (errors / 106 tests) - Productivity (Lot / FTE / day) - Efficiency ($/Lot)
• Measure from your customers POV - Dispositioned On Time (%) - QA Lead Time (days)
• Plan to average = plan to fail
Measure (v): 4. the extent, dimensions, quality, etc., of something, ascertained especially by comparison with a standard.
LEAN
Key Learnings:
• Operational Excellence Initiative
• Internal certification (GB & BB)
• New employees with lean / 6 backgrounds
• Lab processes ideal fit for lean 6 tools - Raw materials - Packaging materials - Bulk & finished product - Sample preparation - Methods
• Staff development
• Re-deployment
Lean Six Sigma (n): a managerial approach that combines Six Sigma methods and tools and the lean manufacturing/lean enterprise philosophy, striving to eliminate waste of physical resources, time, effort and talent, while assuring quality in production and organizational processes.
DESIGN
Example: Lean / flexible lab design for new factory
Successes
• Sampling process
• Lab workflow
• Laboratory layout
• Quality organization
• Lab workforce design
• Batch paperwork flow
• Batch release process
• Quality event management (QEM) process
Design (n): a. The purposeful or inventive arrangement of parts or details b. A particular plan or method
ALIGN
Key Learnings
• Different metrics Alignment
• Different goals Alignment
• Separate communications Alignment
• “Customer” “Supply Chain Partner”
• Quality products “consistent supply of quality products”
Alignment (n): 4. a state of agreement or cooperation among persons, groups, nations, etc. with a common cause or viewpoint.
Looking forward…
Continue to:
Align across the value chain
Leverage technology (instruments & systems)
Optimize workflows and processes
Maintain gains & ensure robustness of QA controls
Amway R&D: Using the Power of Science to help people live better lives.
12 Amway R&D: Using the Power of Science to help people live better lives.
Thank You
Tom Hines Dept. Manager - Ada Operations QA Amway Corporation [email protected]