Effectiveness of a manufacturing process?

[PeterL]

ISO/TS 16949 says in 8.2.2.2 "The organization shall audit each manufacturing process to determine its effectiveness". What does effectiveness mean here?

I'd say that a manufacturing process that delivers first quality product to the customer at the right price on time is effective. But this assessment is best made at management review and not during an internal audit of an individual process.

I'd welcome your opinions.

Peter

 

[Kevin Mader]

How do we know if the manufacturing process is effective as you say? What evidence would you show us?

Regards,

Kevin

 

[PeterL]

The evidence I would present depends on the definition of effectiveness of a manufacturing process. That's my issue. I'm sure ISO had a definition in mind, but did not attach a glossary to TS. As far as I know, there are no sanctioned interpretations for TS.

If I were to use my definition, I would look at all internal audits wholistically during management review and assess the effectiveness of the manufacturing process or processes.

Peter

 

[db]

Effectiveness?

I'd say that a manufacturing process that delivers first quality product to the customer at the right price on time is effective.

Pete, if the process delivers quality product to the customer, but each piece must be reworked two or three times, is it still effective? Or, would you consider it effective, but not effecient?

But this assessment is best made at management review and not during an internal audit of an individual process.

This is an interesting point. As in the case of 8.2.2.3, I'm not convinced the requirement is conduct either of these during the internal audits. I think they are just forms of internal audits. I base this on 8.2.2.3 where it states: “…at appropriate stages of production and delivery…”. To me this indicates that 8.2.2.3 replaces the old “dock audit” of QS. BTW, don’t look for any help in the IATF Guidance document all it says under this section is: “There are many approaches to analyse quality management system, product quality and process performance. In the context of the internal audit clause, internal audit for the organization should be independent of those having direct responsibility for the work performed. Personnel should not audit their own work”

It seems to me that what they are looking for here is some form of independent analysis of process effectiveness. This could be performed in the management review, but there needs to be some record of it.

 

[Mike S.]

Jim Wade said:

Isn't the effectiveness of a process measured purely and simply by the degree to which its outputs deviate from their planned objectives?

rgds Jim

Agreed. Wow, that's 3 times this week!

 

[db]

Not quite

Okay, what the heck.....................

Isn't the effectiveness of a process measured purely and simply by the degree to which its outputs deviate from their planned objectives?

I'm afraid you've got it backwards there Jim. I believe you have described the process ineffectiveness. Process effectiveness would be the degree to which its outputs are consistent with their planned objectives.

Not to split hairs, play semantics or anything.

 

[Sam]

Effectiveness = Ability to achieve desired results.

Efficiency = Results acheived vs resources used.

 

[Geoff Cotton]

Folks,

We measure our manufacturing process effectiveness by using the following Key Business Metrics:

Internal DPMO
External DPMO
Sigma Rating
Line Plan Achievement
Labour Efficiency
Overtime
Rework / Sorting
Scrap

We also measure:

Process Yield
Machine Utilisation
Tooling Usage

 

[Randy]

I like Sam's way of putting it (Semper Fi buddy). It's simple and not confusing. It can also be expanded, such as the way Geoff puts it, if necessary.

I'm going to adopt what Sam said in some of my training presentations.