Transcript Real Time Performance

a
small
business
perspective &
9103
presented to:
IAQG
presented by:
Brian Harvey
Quality Manager – Clamonta Ltd
agenda
• morning presentation
– how a small business implemented 9103
• afternoon break out session
– 9102 FAI process improvement software
presented by:
Brian Harvey
located:
employees:
sales:
established:
manufactures:
approvals:
Nuneaton, Warwickshire, UK
45
£4.25 million
1960
components & assemblies
9100 & NADCAP
continuous
improvement
strategy
5s
process
improvement
charting
kaizen
EFQM
9103 barriers
1.
2.
3.
4.
5.
6.
middle management
cost/benefit
communication
training
data collection method
product type
process improvement charts:
individuals X
1. text message or e-mail to process owner
2. cause & corrective action from chart owner
1. measurement
data
discovering
the
2. equipment
3. batch/job
number
truth about
our
4. date & time
5. location
processes and
training our
people at the
same time
UCLx
LCLx
Real Time Process Improvement
facilities layout
mill
office
cell
repeater
grind
cell
& strangers
turn
cell
heat
treat
ndt
lock
plate
runners
cell
repeater & strangers
• 300 parts/ month
• batch sizes 1 to 24 off
• repeat 1 to 5 years
January 2003
September 2003
1 person running
2 CNC lathes
repeaters
& strangers
results
WITH
3 month trial
40 parts numbers
4000+ measurements
4 non-conforming parts
failure
quality
costs
WITHOUT
failure
4 people running 8 CNC
lathes
appraisal
appraisal
average 40 part numbers each
200+ non-conforming parts
prevention
before
prevention
after
runners
• 55 part numbers
• 65000 parts / year
• batch sizes 100+
• repeat 1 to 4 months
Cpk improvements
• milling fixtures problems < 1.33 Cpk
• our team solved that problem
• now >1.66 Cpk
(parts per million)
runners ‘cell’ results in <5 years
• <½ resource
• 35% more product
• in-process inspection only
• zero delivered non-conformance
• <£4K internal scrap (£950K turnover)
9103 savings
1. reduced non-conformance
2. improved root cause problem
resolution
3. increased efficiency
4. improved flow
Clamonta Ltd
Whitacre Road
Nuneaton
Warwickshire
CV11 6BX
United Kingdom
Tel:+44 (0) 24 76382447 / 76370307
Fax:+44 (0) 24 76381312
hand over
to Delta
thank
you
Dave Wentworth
[email protected]
www.clamonta.co.uk