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Tailoring your Quality ManagementSystem in a Competitive Marketplace
Heather DriscollInfor Presales Business Solutions Consultant
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The Premise
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Presentation Premise
Manufacturing environment will continue to change rapidly
Competition will be intense
Radically new products and processes will emerge
New management and labor practices will emerge
Manufacturing will remain one of the principle means ofcreating wealth
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Tailoring Quality Management Systems
Tailoring a quality management system to the specificneeds of your organization is easier said than done
What helps this process? Quality system models
Standards (ISO9001, AS9100, TS16949, QSR, ISO13485)
RegulationsAnd Experience
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Customers Expectations
Maximize the value relationships among quality, serviceand price
We can have it all attitude among customers force flexibleand adaptable manufacturing systems
Basis of competing for their business creativity andinnovation
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Manufacturing Response to Customers Expectations
Enhance communication and knowledge-sharing for rapidresponse to market forces
Information and knowledge on all aspects of manufacturing must beinstantly available in a form that can be used for decision making
Global distribution of highly competitive production resources
Skilled workforce is critical for maintaining flexibility and responsiveness
Develop innovative process technologies that supportchange scope and scale of manufacturing
Find the optimum position in a better-faster-cheaper
competitive triangle Optimize responsiveness, quality and profitability of the system
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Case Study
Company
Privately owned
Fabricate complete engine tubeassemblies
1 plant
Objectives
Increase on time delivery
Administration cost reduction
AS9100 certification
Real-time visibility
Challenges
All manual process
Complex aircraft industry requirements
No Quality system in place
Need Lot Traceability
Solution
Infor Visual Quality
Results
Live in 6 months
No addition to IT staff
AS9100 certified
Benefits Productivity increase 10%
Decrease in Admin Costs 15%
Increase On Time Delivery 25%
ROI under 1 year
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What is VQM?
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Infor Visual Quality Management (VQM) What is it?
A highly integrated quality information system that letsquality management and business performance be
managed as strategic issues
One stop shopping for an e-QA system with the abilityto grow our systems as our business needs grow.Our customers appreciate the new quality system
because it allows the company to respond faster totheir questions and requests.
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A Proven Solution
10+ years of development and refinement
Over 600 installs, both domestic and international
Designed to meet various industries Quality needs
Designed with ERP and MES system interfaces in mind
Better yet, VQ is built on QA systems that havebeen in the manufacturing sector for years andsupports our ISO initiatives.
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Benefits of VQM
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Benefits of Visual Quality Management (VQM)
Sixteen fully integrated modules
Built around your business process
Works in parallel with ERP systems Covers all areas of quality management:
Quality Control (SPC, PDM, Inspection, etc.)
Quality Assurance (Documentation, Process Mgmt.)
Supports ISO9001, AS9100, TS16949, etc. efforts (Across the system)
Finance (Cost of Quality)
Management (Advanced Reporting, Audits, etc.)
Since all the data collected is in electronic form theease by which trend analysis is done is a hugebenefit. It answers the question: From a qualityperspective, what should we be focusing on?
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Benefits of Visual Quality Management (VQM) contd
Groupware / Collaboration is built-in
Direct email activation and functionality
Data sharing across modules & functions Real-time To Do Lists for each user
Automatic scheduling and event management
Build and manage teams, groups, etc. Collaborate between employees, supplier representatives, and
customers
Replaced 5 isolated quality system databases with one.Information is more accessible and more accurate, to thebenefit of all quality-related processes . The new systemgives people a single source for data, which has really
improved the information flow within our company. That, inturn, makes many processes more efficient.
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Benefits of Visual Quality Management (VQM) contd
Advanced reporting & EIS functions
Numerous standard reports and tools
32-bit reports / SQL-compliant data Custom reports can draw data from both systems
Features available across the system:
Cost of Quality and Trend Analysis
Object link or embed
Manage quality across multiple plants
Assign tasks/people/deadlines (To Dos)
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VQM Process Flow
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CustomerCustomer
ManagementManagement
FMEAsFMEAs
ControlControl
PlansPlans
QualityQualityPlansPlans
Infor VISUAL Quality Management
SupplierSupplier
ManagementManagementEmployeeEmployee
ManagementManagement
DocumentDocument
ManagementManagementProductProduct
DocumentationDocumentationProcessProcess
ManagementManagementPreventivePreventive
MaintenanceMaintenanceCalibrationCalibration
ManagementManagement
InspectInspect
Data CollectionData CollectionSPCSPC
NCMNCM
NonconformanceNonconformance
ManagementManagement
PCAPCA
Preventive &Preventive &
Corrective ActionCorrective Action
COQCOQ
Cost OfCost Of
QualityQuality
Audit ManagementAudit Management
APQPAPQP
AdvancedAdvanced
ProductProduct
QualityQuality
PlanningPlanning
PPAPPPAP
ProductionProductionPartPart
ApprovalApproval
ProcessProcess
Task and TeamTask and Team
ManagementManagementReportsReports
Project ControlProject Control
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Customer Management
Customer list
Unlimited number of entries
Complaints, questions, RFQs, suggestions
Contract reviews
Customer survey generator/manager
CustomerCustomer
ManagementManagement
Our customers appreciate the new qualitysystem because it allows the company torespond faster to their questions and
requests for documents.
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Supplier Management
Supplier inventory
Unlimited number of entries
Approved supplier list
Supplier survey generator/management tool
Manage feedback, suggestions, complaints, RFQs
Allows documentation and automation of supplier ratingsprocess
SupplierSupplier
ManagementManagement
Ability to capture receiving data (actualreview as well as receipt of necessarydocuments) promptly and with reduced
paperwork.
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Employee Management
Employee profiles
Skills, education, certifications
Job descriptions, surveys and performance reviewsTraining records and course scheduling
Employee contact log
Suggestions, peer reviews, attendance, etc
Project Teams
Meeting agendas and minutes
Action items with responsibilities & due dates
EmployeeEmployee
ManagementManagement
Improved training record keeping for
employees
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Document Management
Setup and Administration
Master list of documents
Approval and distribution listsOriginal documentation location
Utilize existing document with link
Indexing and Management
On-line company dictionary
Revision, Notification, and Distribution
Check Out/ Check In
Schedule and record document Audits
DocumentDocument
ManagementManagement
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Product Data Documentation
Master list of part documents
Manage change requests
Schedule and record document audits
Inventory all products and characteristics
By customer or supplier
On-line inspection and test instructions
Basis for inspection plans and control plans
FMEAs (Potential Failure Mode and Effects Analysis)
Understanding critical or key characteristics andknowing where to sample vs. 100% inspect.
ProductProduct
DocumentationDocumentation
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Process Management
Define inputs/outputs
Customer focused
PROCESS - part number independent
Based on IPM methodology (KIV/KOV)
Three level modeling and documentation
Area, activity and key element(s) or critical characteristic(s)
Manage change requests
We created 18 Product families in Process and thusreplaced monitoring and managing 5000 parts.
ProcessProcess
ManagementManagement
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Preventive Maintenance
Inventory of all capital equipment
Handle 1-n components
Preventive maintenance scheduling
by Calendar, Usage or Both
Reactive maintenance documentation
Maintenance tracking - parts/ labor hours
Spare parts inventory
PreventivePreventive
MaintenanceMaintenance
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Calibration Management
Inventory of all measuring equipment
On-line calibration instructions
Schedule & record calibrations and gage studies
Allow for multiple characteristics per device
Graph calibration results - interval analysis
Device check in / check out
CalibrationCalibration
ManagementManagement
Software keeps records about all calibrated devices. Not only is itimpossible for devices to fall through the cracks, the new approachhas eliminated a lot of document handling. We were planning onhiring one more person in the calibration lab to keep up with our
growth, but that is no longer necessary.
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Inspection
Linked to specs in PDM and Process management
On-line viewing work instructions and blueprints
On-line data collection for receiving, in-process and out-going final audit
Linked to Nonconformance Management
Cp/Cpk, PPM and other reporting by gauge, machine, operator, supplier, operation,
part #/characteristic, time period, serial number, etc.
Parts specific controls plans
SPC charting via collected data from Product and Processcharacteristics. We have learned first hand, by controlling
our data, we continue to control our costs.
InspectInspect
Data CollectionData Collection
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VQM Statistic Process Control (SPC)InspectInspect
Data CollectionData Collection
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Nonconformance Management
Single system to track all nonconformances
Internal issues (part specific and system issues)
Customer complaints, returns and warranty Supplier issues
Can be entered manually or automatically posted fromproduct and process test results
Tracking by defect type, vendor, part number, program, cause,plant/division, etc
Dispositions (multiple) and Approvals
Verification
Linked to associated Corrective and preventive actions
Maintain audit trail
NCMNCM
NonconformanceNonconformance
ManagementManagement
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Nonconformance Management
The softwares use of pre-established values for
specific data fields has improved the uniformity ofnonconformance reporting. These NCM reports,now digital, are stored on the server and availableto those who need them from their PCs. Access isimmediate. This alone has reduced cycle time forhandling NCMs from weeks to minutes. Theimprovements in reaction time and cycle time have
been phenomenal. In addition, two peoplepreviously dedicated to filing NCM forms havebeen reassigned to other work.
NCMNCM
NonconformanceNonconformance
ManagementManagement
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Preventive and Corrective Action
Inventory of all preventive & corrective actions
Generated internally, by the customer or issued to Suppliers
Manage different types of corrective actions
Identify by part #, supplier, NCMs, etc.
Assign employees and due dates
Record-keep all related meetings and action items
Assure effectiveness through scheduled follow-upsAutomatic re-generation of failed corrective actions
Maintain audit trail
PCAPCA
Preventive &Preventive &
Corrective ActionCorrective Action
Project ControlProject Control
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PPAP
Understand yields before full production begins
Contains all Elements of PPAP
(Production Part Approval Process) or trial runsProvides management of each PPAP element
Complete change control and traceability
Each element pulls data from other VISUAL Qualitymodules, or you can use links to existing documentation
PPAPPPAP
ProductionProduction
PartPart
ApprovalApprovalProcessProcess
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APQP
Structured around the 5 step APQP (Advanced ProductQuality Planning) process
Pulls information from other VQ quality systems like PPAPsystem (real-time information)
Full status tracking and management of allelements/checklists of APQP
APQPAPQP
AdvancedAdvanced
ProductProductQualityQuality
PlanningPlanning
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Audit Management
Auditing structured around your system
Generation of checklists/questions or link to associatedaudit documents
Generation of audit schedules with copy features forgenerating 3 to 5 year plans
Documentation of observations, findings, nonconformance,and corrective actions
Audit ManagementAudit Management
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Cost of Quality
Automatic posting from other modules
Categorize appraisal, preventive, internal andexternal failure costs into an unlimited number ofcategories
Analyze against unlimited number of measurementbases
Provides true activity based quality costing
COQCOQ
Cost OfCost Of
QualityQuality
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Cost of Quality contd
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Summary
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VISUAL Qualitys Value to your Organization
The Infor Visual Quality Management provides asolution for success including the tools to:
Tailor your Quality System for optimal competitiveposition
Standardize your Processes
Collaborate with your suppliers, customers, partners
Secure senior executive support to drive systemadoption and compliance
Implement Early Warning Programs for defectivematerial and/or delivery issues
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Summary
As you can see, the Infor Visual Quality solutionprovides many opportunities to increase efficiencyand reduce nonconformances, thereby decreasingcost of goods sold and increasing earnings.
As stated earlier, tailoring a quality managementsystem to the specific needs of your organization iseasier said than done.
Utilizing one integrated quality assurance system begins thejourney of moving from isolated islands of systemsinformation to one comprehensive solution.
We provide the people and the tool to help you achieve andmaintain your specific goals.
Thank you for your time and participation!