Interim Control Plans

G

GregRus

#1
I've recently started in a machine shop as QE and am trying to make needed improvements. Currently there are no work instructions, process flow diagrams, P/DFMEAs, MSA or control plans. The calibration system is under control and the shop floor operators/machinists are pretty skilled.

I'm trying to balance short term solutions vs long term ones. For short term I plan to use process control plans to start to help with customer returns. Above mentioned tools would follow afterwards.

Any thoughts on this approach? Thx
 
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Jim Wynne

Leader
Admin
#3
You don't say what type of market(s) you're dealing with, but in any event you should remember that the key in process control plans is having a plan for process control. Simply establishing inspection requirements by edict won't help much in the long run. You need to find out why the customer returns are happening and get control of that.
 
G

GregRus

#4
Thanks for the response Jim. We make various parts used in industrial applications.
The customer returns are manufacturing defects. There is a real lack of any quality system in place. Right now I'm in fire-fighting mode. My short term intent is to instill some order in some areas and then drive more permanent solutions but this will take some time.
I've been peeling back the onion but am starting to cry.
 
G

GregRus

#5
In retrospect maybe the broader question should have been when walking into a manufacturing organization like this with next to nothing for a quality management system where is the best place to start?

I'm trying to get my arms around the beast.
 
O

oldmanian

#6
Greg,
The beast can be hard to attack. I know, when we started on the road to ISO certification we had returns above 7.5%. We decided to concentrate on the returns first and we established a ranking of the parts returned. Concentrating on the part with the largest number of returns we found the main reasons for the rejects and then set up controls over those defect causes, plating, inspection measurements, damage in transit etc.
We found after ten or so products that the reasons for the returns were similar in a lot of the cases. This allowed us to put in place across the board controls for these causes. Attacking the major causes of rejects allowed us to control over 80% of the causes of rejects. Maybe that is a start point for you. Get a plan for control and then chip away at the beast.
 
S

Shetudubey

#7
Hi GregRus,

I am in same situation that you are in. The way i would do is first get the current work instructions for all the processes. Then compare them with the customer complaints root causes and see what is missing in the work instructions. The key is to understand what is being done and then compare it with what needs to be done. I hope this helps!!!
 
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