Tailoring your Quality Management System in a Competitive Marketplace

Heather Driscoll Infor 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 of creating wealth

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Tailoring Quality Management Systems Tailoring a quality management system to the specific needs of your organization is easier said than done What helps this process?
Quality system models Standards (ISO9001, AS9100, TS16949, QSR, ISO13485) Regulations

And Experience

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Customers Expectations Maximize the value relationships among quality, service and price We can have it all attitude among customers force flexible and adaptable manufacturing systems Basis of competing for their business creativity and innovation

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Manufacturing Response to Customers Expectations Enhance communication and knowledge-sharing for rapid response to market forces
Information and knowledge on all aspects of manufacturing must be instantly 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 support change 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 tube assemblies 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 lets quality management and business performance be managed as strategic issues

One stop shopping for an e-QA system with the ability to grow our systems as our business needs grow. Our customers appreciate the new quality system because it allows the company to respond faster to their 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 have been in the manufacturing sector for years and supports 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 the ease by which trend analysis is done is a huge benefit. It answers the question: From a quality perspective, 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 the benefit of all quality-related processes . The new system gives people a single source for data, which has really improved the information flow within our company. That, in turn, 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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Infor VISUAL Quality Management

Supplier Management Customer Management Employee Management APQP Advanced Product Quality Planning FMEAs Control Plans Inspect Data Collection NCM SPC Nonconformance Management PCA Preventive & Corrective Action Project Control Task and Team Management Reports Quality Plans PPAP Production Part Approval Process

Document Management COQ Cost Of Quality

Product Documentation

Process Management

Preventive Maintenance

Calibration Management

Audit Management

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Customer Management Customer list Unlimited number of entries Complaints, questions, RFQs, suggestions Contract reviews Customer survey generator/manager Customer Management

Our customers appreciate the new quality system because it allows the company to respond faster to their questions and requests for documents.
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Supplier Management Supplier inventory Unlimited number of entries Approved supplier list Supplier Management

Supplier survey generator/management tool Manage feedback, suggestions, complaints, RFQs Allows documentation and automation of supplier ratings process Ability to capture receiving data (actual review as well as receipt of necessary documents) promptly and with reduced paperwork.
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Employee Management Employee profiles

Skills, education, certifications Job descriptions, surveys and performance reviews

Employee Management

Training records and course scheduling Employee contact log

Suggestions, peer reviews, attendance, etc

Project Teams
Meeting agendas and minutes Action items with responsibilities & due dates

Improved training record keeping for employees

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Document Management Setup and Administration

Master list of documents
Approval and distribution lists Original documentation location Utilize existing document with link

Document Management

Indexing and Management On-line company dictionary Revision, Notification, and Distribution Check Out/ Check In Schedule and record document Audits

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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

Product Documentation

Basis for inspection plans and control plans FMEAs (Potential Failure Mode and Effects Analysis) Understanding critical or key characteristics and knowing where to sample vs. 100% inspect.
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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)

Process Management

Manage change requests

We created 18 Product families in Process and thus replaced monitoring and managing 5000 parts.
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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 Preventive Maintenance

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Calibration Management Calibration Inventory of all measuring equipment Management 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
Software keeps records about all calibrated devices. Not only is it impossible for devices to fall through the cracks, the new approach has eliminated a lot of document handling. We were planning on hiring one more person in the calibration lab to keep up with our growth, but that is no longer necessary.
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Inspection

Inspect Data Collection

Linked to specs in PDM and Process management On-line viewing work instructions and blueprints On-line data collection for receiving, in-process and outgoing 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 Process characteristics. We have learned first hand, by controlling our data, we continue to control our costs.
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VQM Statistic Process Control (SPC)

Inspect Data 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

NCM Nonconformance Management

Can be entered manually or automatically posted from product 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

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Nonconformance Management

NCM Nonconformance Management

The softwares use of pre-established values for specific data fields has improved the uniformity of nonconformance reporting. These NCM reports, now digital, are stored on the server and available to those who need them from their PCs. Access is immediate. This alone has reduced cycle time for handling NCMs from weeks to minutes. The improvements in reaction time and cycle time have been phenomenal. In addition, two people previously dedicated to filing NCM forms have been reassigned to other work.

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Preventive and Corrective Action

PCA Preventive & Corrective Action Project Control

Inventory of all preventive & corrective actions Manage different types of corrective actions Identify by part #, supplier, NCMs, etc. Assign employees and due dates

Generated internally, by the customer or issued to Suppliers

Record-keep all related meetings and action items Assure effectiveness through scheduled follow-ups Automatic re-generation of failed corrective actions Maintain audit trail

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PPAP Understand yields before full production begins Contains all Elements of PPAP (Production Part Approval Process) or trial runs
PPAP Production Part Approval Process

Provides management of each PPAP element Complete change control and traceability Each element pulls data from other VISUAL Quality modules, or you can use links to existing documentation

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APQP Structured around the 5 step APQP (Advanced Product Quality Planning) process Pulls information from other VQ quality systems like PPAP system (real-time information) Full status tracking and management of all elements/checklists of APQP
APQP Advanced Product Quality Planning

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Audit Management Auditing structured around your system Generation of checklists/questions or link to associated audit documents Generation of audit schedules with copy features for generating 3 to 5 year plans Documentation of observations, findings, nonconformance, and corrective actions Audit Management

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Cost of Quality Automatic posting from other modules Categorize appraisal, preventive, internal and external failure costs into an unlimited number of categories Analyze against unlimited number of measurement bases Provides true activity based quality costing

COQ Cost Of Quality

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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 a solution for success including the tools to: Tailor your Quality System for optimal competitive position Standardize your Processes Collaborate with your suppliers, customers, partners Secure senior executive support to drive system adoption and compliance Implement Early Warning Programs for defective material and/or delivery issues

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Summary As you can see, the Infor Visual Quality solution provides many opportunities to increase efficiency and reduce nonconformances, thereby decreasing cost of goods sold and increasing earnings. As stated earlier, tailoring a quality management system to the specific needs of your organization is easier said than done.
Utilizing one integrated quality assurance system begins the journey of moving from isolated islands of systems information to one comprehensive solution. We provide the people and the tool to help you achieve and maintain your specific goals.

Thank you for your time and participation!

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