Quality Management System
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Quality Management System
Implementation Engineers implements holistic Quality Management Systems (QMS) for clients to enhance product quality, quality processes, and organizational accountability. By improving and standardizing work procedures, implementing control plans, and utilizing as appropriate real-time monitoring tools such as trending dashboards with SPC control limits, we support our clients in achieving improved process control and consistent quality standards across their operations. An effective QMS supports clients with regulatory requirements and industry standards, and also drives cost savings, increased productivity, and a better overall customer service level and reputation.
85% reduction in out of spec foundry compactibility
76% reduction in out of spec foundry green strength
$2.3M project benefits
IX® in Action
Our client operated a connectors facility that included foundry operations. Facing OEE losses due to operations and quality issues, there arose a pressing need to recover losses, boost effective capacity, meet demand, and eradicate backlog. The primary root cause issues identified in both operations and quality measurement systems were sand-related challenges. Improving sand system process capability and measurement systems emerged as a critical area for enhancement. To address these challenges, our client partnered with IE to implement a comprehensive Quality Management System (QMS). Activities during IX® included:
- Implemented new measurement systems that allowed for more accurate tracking and easier use of scrap and downtime data
- Created a format for meetings using the new measurement systems, where data could be utilized to develop a plan to address scrap and downtime related issues
- Initiated scrap RCCA meetings based on the results of both MRB data and tablet data collection
- Utilized the Ishikawa diagram tool during meetings to identify possible causes of the top scrap reason code
- Established proactive leader routines on all 3 shifts with all 3 foundries by identifying critical control points and defining expectations for corrective actions
- Standardized work procedures for Startup, Operation, and Shutdown processes, as well as for Preventive and Autonomous Maintenance, Trouble-Shooting, Root Cause Corrective Action, Daily Management, and Gemba Audits
- Developed and implemented control plans for all three foundries to ensure consistent quality standards and process control
- Introduced Batch and Shift "real-time" trending dashboards, utilizing Statistical Process Control (SPC) control limits to monitor production performance and identify deviations for prompt quality control decisions
- Enhanced communication, engagement, training, and coaching with leaders and operators
