Continual Improvement of Production Processes - TS 16949

A

antje

#1
According to the ISO/TS chapture 8.5.1.2 you have to improve always the production processes. We have one process running since 10 years and deliver e.g. less than 100 ppm in a month. Therefore, we do not want change anything in this process. What arguments did we have therefore to the auditor? Anybody a good idea?

Antje
 
Elsmar Forum Sponsor
M

M Greenaway

#2
Tough question.

Assuming that all your production processes are capable of achieving such levels of product conformance then you could perhaps turn your efforts to improving efficiency or reducing costs, or even improving the product itself. Or look at the 'service' side of the business, such as delivery performance, etc.

If you have already achieved all this then you are perhaps quite a unique company !!
 
P

paulnguyen

#5
Hi,
IMO, PPM target is set differently from customer to customer pending on type of process, product and other historical factors.

For the continual improvement, analysis from the results of current PPM status, leading to actions to improve the process in order to reduce the PPM, or even leading to the determination of lower priority than other needed action plans (case of the target PPM has been met) is still acceptable, I think.

Paul N.
 
R

Randy Stewart

#6
PPM Numbers

PPM is another statistic that can really mess up a company. You must look at what your volume of shipping is first. If it is a low volume it may not tell you anything, especially if the reject numbers are inflated. Here's an example, Company Q supplies parts to Company K on a low volume scale (< 8000 per year). Parts are shipped in racks of 10 parts per. Company K rejects in lots and finds 1 part with shipping damage in each of 2 racks. Company K reports rejecting 20 parts and Company Qs PPM goes through the roof (somewhere around 250,000). Now is that a good reflection of what Company Q's quality is? I say no. If you look at the 6 month or 3 month PPM it may but the company will spend most of the next 12 months trying to reduce the PPM (annual average) because of the amount of parts being shipped. Company Q could show great improvment on reducing the PPM but what do they gain from it? For the Process Improvment initiative look at scrap reduction, just because you deliver < 100 PPM per month doesn't mean there isn't a lot of sorting or scrap. Maybe quicker set up time, etc. As an auditor I would be curious if a process hasn't changed over a 10 year period, I'm not stating that it couldn't but with all the changes in industry it would be a dinosaur if it hasn't been changed at least a couple times.
 
#7
The real issue is "improvement". Reduction of PPM is only one way to 'improve' the process. From the customer's viewpoint, you can make significant advances in the service aspects with this product that would constitute 'improvement'. Investigate all parts of the value chain.

Also, we have had some success in the past by demonstrating how our prioritization of resources for improvement activities has resulted in an overall improved relationship with the customer. But our actions were not directly related to the output of the production process. Depends on the auditor and registrar, talk to them, you pay the bill!
 
M

M Greenaway

#8
Another angle would be to consider other 'interested parties' such as stakeholders or employees, by for example improving share dividends or reducing absence or staff turnover.

If you production processes are so good (which is probably questionable) then turn your attention to these areas.
 
I

IceZebra

#9
Look at 8.5.1.1

The ISO/TS 'bible' does not state that you must improve ALL processes. What it does say (in 8.5.1.1) is the organization must define its process for continual improvement. It is up to the organization how they do this.
Somehow, you need to prioritize your improvement efforts and if your 100 PPM process does not bubble to the top of the list for your company, then you shouldn't need to argue with your auditor at all. Just make sure that you have backup information showing that there are other processes within your organization that require focused efforts, other than this one.
 

rmundroff

Starting to get Involved
#10
Re: TS 16949 - Continuous Improvement of Production Processes

Another way to look at this is the ranking of your PPM's, similar to RPN's on PFMEAS. You may not be able to do all your lines at once, but based on RPN, PPM, Volume, Cost, Customer, etc. you may have to prioritize what needs to be done. Also can there be small improvements (layout, Ergo, etc.) that may help drop from 100 to 99 PPM, or maybe reduce stress & strain injuries, or improve cycle time by a sec or two. All improvements, but not necessary "Quality" improvements.
 
Thread starter Similar threads Forum Replies Date
B Four Key Performance Indicators for Continual Improvement (Dec. 3 2019) [Deleted] Training - Internal, External, Online and Distance Learning 2
R Linking the Processes of Continual Improvement, Change Management, Risk Management, Action Planning, etc? Preventive Action and Continuous Improvement 5
A A Question about Continual improvement process in AS9100 AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
B Ranking Continual Improvement Projects Quality Tools, Improvement and Analysis 5
J Understanding ISO 9001:2015 - 10.3 Continual Improvement ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
P CA,PA, Continual Improvement - How to start in a Service Company Quality Tools, Improvement and Analysis 1
Marc How will "continual improvement" be audited? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 4
B Internal Audit Question - 8.5.1 Continual Improvement ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 23
M Continual Improvement Procedure - Please review Document Control Systems, Procedures, Forms and Templates 1
P Document Control vs Continual Improvement Document Control Systems, Procedures, Forms and Templates 11
C Continual Improvement in the context of ISO 22000:2005 Preventive Action and Continuous Improvement 2
Q Process Approach & Continual Improvement Clauses and Evidence of its Effective Use ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 9
S Continual Improvement vs. Ineffective Actions AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
A Definition Continual Improvement vs. Kaizen - Differences Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 6
Icy Mountain Continual Improvement, Preventive Action and Corrective Action Database Quality Tools, Improvement and Analysis 23
T TS 16949 Continual Improvement Requirements vs. QS-9000 Requirements IATF 16949 - Automotive Quality Systems Standard 16
somashekar Environmental and OH&S Management Continual Improvement Miscellaneous Environmental Standards and EMS Related Discussions 7
V Continual Improvement of the Organization - TS 16949 Clause 8.5.1.1 IATF 16949 - Automotive Quality Systems Standard 10
S Continual (Continuous) Improvement - Different Standards, different requirements Occupational Health & Safety Management Standards 12
I Process Improvement/Continual Improvement "Idea Stage-gate" process? Misc. Quality Assurance and Business Systems Related Topics 3
N Continual Improvement Tools Preventive Action and Continuous Improvement 3
R Definition Continuous Improvement and Continual Improvement - Differences Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 21
A Clause 8.5 Continual Improvement - What is intended by the standard? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
B Quality Policy - Need to include "Customer Satisfaction & Continual Improvement? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
somashekar Temperature Cycling Process - Continual Improvement and ISO 13485 ISO 13485:2016 - Medical Device Quality Management Systems 6
M Continual Improvement & KPI's (Key Performance Indicators) - ISO 14001 REACH and RoHS Conversations 23
V Gearing up GMP based systems for continual improvement. US Food and Drug Administration (FDA) 4
Anerol C What can I show as evidence of Continual (Continuous) Improvement? Preventive Action and Continuous Improvement 81
B 8.5.1 Continual Improvement - What Quality Objectives can I add? Construction ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
Z Continual Improvement based on a Company's Characteristics Preventive Action and Continuous Improvement 6
L Introduce Continual Improvement in a Mining Equipment Service Company ? HOW? Quality Tools, Improvement and Analysis 5
R Jump Start Continual Improvement Process - What works? Preventive Action and Continuous Improvement 9
V TQM - Implementing Continual Improvement of Product, Processes and System Misc. Quality Assurance and Business Systems Related Topics 1
B Continual Improvement Requirements - No expected completion date listed - 8.5.1 IATF 16949 - Automotive Quality Systems Standard 10
B Continual Improvement form - Does anyone have a CI form they will share? Preventive Action and Continuous Improvement 2
C Process Goals - Stretch or "Do-able": Corrective Actions or Continual Improvement Preventive Action and Continuous Improvement 6
M Setting Objectives and Targets for the EMS - Is continual improvement required? Miscellaneous Environmental Standards and EMS Related Discussions 23
J Continual Improvement - Service Company - Carpool, manpower, purchasing, logistics Service Industry Specific Topics 1
P Continuous vs. Continual Improvement - The Differences Preventive Action and Continuous Improvement 9
L Records of continual improvement - How do you keep auditors happy on this topic? Records and Data - Quality, Legal and Other Evidence 11
J Continual Improvement - What is CI and what is CI not? Preventive Action and Continuous Improvement 32
Marc The Continual Improvement Process (vs. Continuous Improvement?) Book, Video, Blog and Web Site Reviews and Recommendations 6
ccochran Continual Improvement Book Book, Video, Blog and Web Site Reviews and Recommendations 14
Q Difference between Continuous and Continual Improvement IATF 16949 - Automotive Quality Systems Standard 8
C Evidence of Continual Improvement ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
R Anyone have a procedure to share for TS 16949 - 8.5.1 Continual Improvement? IATF 16949 - Automotive Quality Systems Standard 3
A Is reduction of scrap a valid Continual Improvement Project? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 7
K Continual Improvement & Preventive Action Differences ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 7
L ISO 14001 - Environmental Management Program - To govern continual improvement? ISO 14001:2015 Specific Discussions 6
J Continual Improvement vs. Continuous Improvement - Terminology Semantics ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 16

Similar threads

Top Bottom