Our process and quality related service offerings range from process development through validation and continuous improvement of existing manufacturing processes. Please contact us to discuss how we can meet your particular service needs. We believe we can address any process or quality issue you may be facing. We want to show you how to reduce defect rates, reduce scrap costs, and add to your bottom-line savings. A few of the services Process and Quality Control Solutions provides:
- Problem Capability Analysis and Improvement
- Complex Problem Root Cause Analysis
- Measurement System Analysis
- Repeatability and Reproducibility Analysis and Improvement
- Process and Quality Control Documentation
- Statistical Process Control Design and Analysis
- Process and Quality System Audits / Audit Planning
- ……. and More!
Process Capability Analysis
Process and Quality Control Solutions can analyze and break down your data to define predictable process results and opportunities for variation reduction.
A typical automotive O.E.M. customer requests that their suppliers demonstrate a process capability of 1.33 to 2.0 Cpk. These targets are set to minimize the predicted defect rate. It is not uncommon for suppliers to fail a basic Cpk analysis even though a thorough study of their non-normal, but predictable process would show an acceptable Cpk equivalent defect rate.
No one, including your customer, should expect you to potentially shorten the life of your tooling and risk project delays with non value added, expensive tool modifications. We can help you with a thorough analysis of your true process capability.
Documenting Process and Quality Controls
Process and Quality Control Solutions can guide you in the documentation of an effective Quality Control System. This begins with a well-defined map, or Process Flow Diagram. We’ll insure that there are clear measurement systems and targets for the required process outputs as well as measures and controls for the significant inputs that will drive these desired outputs. After defining and accounting for all significantly contributing inputs beyond our basic process controls, we will define our improved process control limits to drive the output within a target range while protecting the process from those inputs we cannot control or those we choose not to control.
We should manage this process control through Process Control Plans, Operator Instructions, Equipment Specifications, Statistical Process Control, or other key controls designed to keep these process inputs within a range we desire. The controls we will select will evolve from a process input focused Process Failure Mode Effects Analysis. Our approach will go beyond a brain-stormed list of potential process detractors. We will build a PFMEA based upon potential control failures of our complete list of proven, significant process inputs. This will guide us to the planning and documentation of systems that define Process and Quality Control Solutions which will most effectively manage the connection between the desired outputs and the key process inputs that drive them.
Identifying Key Process Inputs
Process and Quality Control Solutions will focus on the identification and management of critical process inputs. P&QCS will show you how to identify potentially unrecognized process inputs and how to manage the significant process inputs gain effective control of the variation in your desired outputs.
We are experienced in the use of Design of Experiments (DOE) and other formal analysis tools which can be very effective in the definition of significant process inputs and their optimum settings. These tools also allow us the opportunity to evaluate factor interactions and the relative influence of each factor as the process runs in manner closest to real world, manufacturing conditions. This can be managed while evaluating multiple factors and factor-levels.
We can take this concept further as we look at multiple, potentially optimum, settings for multiple factors. These results from a complex molding process DOE provided the information we needed to define critical process settings. This was after the experienced process engineers and material supplier had run out of ideas. These 7 factors with 3 levels each were evaluated using a single DOE and then verified using the optimum level for each. The disciplined problem solving approach saved both time and money.
Implementation of Statistical Process Control
Process and Quality Control Solutions will take you beyond the basic idea that Statistical Process Control (SPC) equals a heavy application of X-bar & R charts. There are many valid applications for X-Bar & R charts as well as other control chart types. Over-whelming a group with the wrong chart types, charts applied to the wrong process indicators, or multiple layers of charts maintained for the same process is inefficient at best. X-bar & R Charts should not necessarily be your ultimate process control solution. We can help you to select the most effective process (variation) indicator and the appropriate process control.
P&QCS supports the use of control charts, but likes to promote an active DMAIC approach to control chart applications. X-bar & R charts can be effectively implemented to give nearly real-time control of your processes. The timely entry of data and check against acceptance criteria is a critical first level to a good SPC program. Simple records of the Out of Control Root Cause or basic records of coincidental observations move you to a second level. Putting these recorded observations in the form of a Pareto chart can give you a priority for process variation drivers to attack. Using the information to update your PFMEA and control documents to eliminate these unwanted influences will reduce process variation. This would be an improved level 3 of SPC and the point for resuming this continuous improvement (DMAIC) activity.
Audits and Audit Planning
Process and Quality Control Solutions is experienced and trained in the performance of VDA 6.3, TS 16949, and ISO 9000 audits. P&QCS is also experienced at setting up internal and supplier audit plans.
We understand that almost no one is happy to hear that the auditors are coming. P&QCS can help you prepare for a standard process audit.
We can also assist you in the development of your own quality system audit plans and the training of your auditors.
We can guide you through Zero Acceptance Number Sampling Plans (c=0 sampling plans).
P&QCS can assist with detailed supplier process audit plans.
Measurement System Analysis
Process and Quality Control Solutions is experienced in the development and analysis of measurement systems. The process of collecting your data is extremely important. Bad data can lead manufacturers to incorrect conclusions and poor decisions. P&QCS understands the important distinctions between repeatability, reproducibility, accuracy, precision, and other key measurement elements.
There are many elements that go into a reliable measurement system. P&QCS can guide you through the correlation of design, gauge, and process datums. We can conduct R&R studies and show you how to reduce your measurement error.
We can train your employees to use measurement tools.
We can show you how to use your gauge calibration system to reduce measurement error.