New to AS9100 Rev. C - Setting KPIs and FAI Reports

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phillips25m

#1
Hi to all may I introduce myself, my name is Mark and I am an owner of a small grinding Company. We have been told by four of our customers we need to gain AS9100. We have just gone through stage two of our Audit and gained very minor NC against us, which I have worked on and sorted the majority out. But the last two I seem to be struggling with. The first is KPI and the measuring of them, I have only identified three, which are on-time delivery, Non-confirming parts and quotations returned in time. As our company is only a small process and not a complete manufacturing company, we never really had the tools to monitor the on-time delivery. This was a guesstimate to be plain which was set at 95% in the ISO system. But in AS9100 I was given an Excel spreed sheet with a graph which is very nice:applause: We were asked to transfer the information from the job cards we had to see how it worked. But because our customers never gave deadlines on P/O our dates required were filled in ASAP which counts as being on time! So we ended up with a total of 98% on time. I have been told that's what we should put for this years target? So just done the first month and we have not hit that target? People have told me it is up to us to set our desired level for on time deliveries? Can anyone tell me other wise :notme:
The second is 7.5.1 I have been told we must produce a FAIR? Our customers never ask for them, however, some people say I have to have them and be able to do them if I am required to because the standard says you must . And other people are saying "because we don't design we don't need them because grinding is such a small operation" :argue:

Any help would be greatly appreciated.:thanks:
 
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Michael_M

Trusted Information Resource
#2
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

I have uploaded an excel spreadsheet that may be able to help with the FAI. I automated allot of the typing so it becomes easier.

Note: On page 1, I protected most of the cells that do not get changed much (Box 10 on page 1 for example). You will want to put your data in where it belongs then protect the fields.

I type all the data on the last tab "all" and then excel places the data on the correct page. I do this so when I type the same data in frequently it autotypes it and I don't have to retype the same info over and over again.
 

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Big Jim

Super Moderator
#3
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Unless you can justify a reason not to do 7.5.1.1, and claim it as an exclusion, you need to do it. You will probably have a hard time justifying it satisfactorily to your certification body.

7.5.1.1 is often referred to as first article inspection, but don't confuse it with the requirements of AS9102, which is a more involved first article than 7.5.1.1 requires. Since there is often confusion on the topic, I suggest you get a copy of AS9102 so you can compare it to what little there is in 7.5.1.1.

In essence you need to select a representative sample from the first production run and make the assessment, mostly through measurements, that the process and documentation are sufficient to ensure that subsequent parts will continue to meet requirements.

If you think that is a pain, be happy you are not making automotive parts where they require a much more detailed system, that of PPAP.

You need to do it. You might check around with other grinding shops (or possibly machine shops) to see how they do it.
 

ckillam3

Starting to get Involved
#4
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Allow me to also highly recommend a review of AS9101 as the AS9100 auditor will be following this verbiage in his/her work.
 

Mikishots

Trusted Information Resource
#5
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Hi to all may I introduce myself, my name is Mark and I am an owner of a small grinding Company. We have been told by four of our customers we need to gain AS9100. We have just gone through stage two of our Audit and gained very minor NC against us, which I have worked on and sorted the majority out. But the last two I seem to be struggling with. The first is KPI and the measuring of them, I have only identified three, which are on-time delivery, Non-confirming parts and quotations returned in time. As our company is only a small process and not a complete manufacturing company, we never really had the tools to monitor the on-time delivery. This was a guesstimate to be plain which was set at 95% in the ISO system. But in AS9100 I was given an Excel spreed sheet with a graph which is very nice:applause: We were asked to transfer the information from the job cards we had to see how it worked. But because our customers never gave deadlines on P/O our dates required were filled in ASAP which counts as being on time! So we ended up with a total of 98% on time. I have been told that's what we should put for this years target? So just done the first month and we have not hit that target? People have told me it is up to us to set our desired level for on time deliveries? Can anyone tell me other wise :notme:
The second is 7.5.1 I have been told we must produce a FAIR? Our customers never ask for them, however, some people say I have to have them and be able to do them if I am required to because the standard says you must . And other people are saying "because we don't design we don't need them because grinding is such a small operation" :argue:

Any help would be greatly appreciated.:thanks:

Tracking your on time delivery is not an exercise that is solely for keeping auditors happy or for filling up an empty spot in your KPI list; the point of having it is so that you can trend your performance, tell if and when it's going sideways and continually improve it. If the customer simply wants it ASAP, it should make zero difference to you in your trending of OTD.

I'd start by benchmarking a build. When things go right, how long does it take to build it? Do you have any idea? Once that build has been examined and defined, what are some things that you can do to improve the delivery time without compromising the quality (and vice-versa)? The point is to always work towards being faster and better - time is money and poor quality is expensive. Even your long-term customers that have been fine with "ASAP" in the past will be pleasantly surprised when you are able to provide their product quicker each time without a loss in quality, and you will be more profitable by being more efficient.
 

Big Jim

Super Moderator
#6
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Tracking your on time delivery is not an exercise that is solely for keeping auditors happy or for filling up an empty spot in your KPI list; the point of having it is so that you can trend your performance, tell if and when it's going sideways and continually improve it. If the customer simply wants it ASAP, it should make zero difference to you in your trending of OTD.

I'd start by benchmarking a build. When things go right, how long does it take to build it? Do you have any idea? Once that build has been examined and defined, what are some things that you can do to improve the delivery time without compromising the quality (and vice-versa)? The point is to always work towards being faster and better - time is money and poor quality is expensive. Even your long-term customers that have been fine with "ASAP" in the past will be pleasantly surprised when you are able to provide their product quicker each time without a loss in quality, and you will be more profitable by being more efficient.
Tracking on-time delivery really tells you just how effective your quality management system is behaving overall. It will not pin down the exact cause of a problem, but a low number it is an early indicator that something is amiss and needs to be found and corrected. It is a far more valuable indicator than many people give it credit for.
 

Mikishots

Trusted Information Resource
#7
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Tracking on-time delivery really tells you just how effective your quality management system is behaving overall. It will not pin down the exact cause of a problem, but a low number it is an early indicator that something is amiss and needs to be found and corrected. It is a far more valuable indicator than many people give it credit for.
I haven't disagreed with this.
 
P

phillips25m

#9
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Thanks for the replies, i am looking into it a little further, All our KPI's are as follows, On time delivery, Right first time ( non-conforming parts), New customers over a year period and Return of quotations in a time limit. So we are only measuring 4 KPI's. Please take into account we only employ 8 people( big in terms of a specialized stand a lone grinding shop)? So AS9100 is a bit much for our size ? Considering we only carry out a process and we do not make anything from scratch??:notme: All in put welcome :thanx:
 

Big Jim

Super Moderator
#10
Re: New to As9100 Rev C - Setting KPIs and FAI Reports

Thanks for the replies, i am looking into it a little further, All our KPI's are as follows, On time delivery, Right first time ( non-conforming parts), New customers over a year period and Return of quotations in a time limit. So we are only measuring 4 KPI's. Please take into account we only employ 8 people( big in terms of a specialized stand a lone grinding shop)? So AS9100 is a bit much for our size ? Considering we only carry out a process and we do not make anything from scratch??:notme: All in put welcome :thanx:
I call on a two person company that has been successfully registered to AS9100 for about four years.

You can make it as hard to manage as you want.

Four KPIs don't have to be hard to do, unless you want it to be.
 
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