Please Review My Tracking System

NikkiQSM

Quite Involved in Discussions
#1
Hello All -

Attached in the current spreadsheet I use to track CARs, NCMRs (rejections), Rejection percentages, and Customer Complaints.

I have so much information in this spreadsheet. It's making my eyes cross just to log in everything. When it comes time to break down each issue and group them together to point out areas needing improvement, I end up spending hours breaking it all down.

My method of breaking down the information is merely using a notebook and totalling up everything. Putting data together this way leaves too much room for error, IMO.

While it may look like I am over-analyzing everything and breaking everything down WAY too much - My GM requests all this information.

Please take a look and provide me with your opinions on this system.

Maybe you know of something that can work better for me?

I really appreciate any help with this!!! :thanx:
 

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NikkiQSM

Quite Involved in Discussions
#2
Just one more bit of info - When I started with this, we would use CARs for every rejection.

It came down to the point where we would only use CARs for high risk issues that really needed corrective action. For all rejections we would start completing NCMR instead. This would document the rejection but would not require a LTCA.

This is why when you look at this system, you may think I am duplicating efforts... We started using NCMRs in May of 2012.
 
B

bluepagen

#3
That is a lot of information that you track! There was a time when I tracked inspection reports and who inspected and which vendor it came from and reasons for scrap and days to repair, but it seemed like I was the only one that really looked at it.

Is there anything you can eliminate? You certainly have a lot of data, do you use it all?
 

sagai

Quite Involved in Discussions
#4
If you know any IT guys around I would propose to look into customizable tracking systems like TRAC and Redmine.
These are free, all you have to have is someone can set up and maintain it.
Cheers!
 

NikkiQSM

Quite Involved in Discussions
#5
That is a lot of information that you track! There was a time when I tracked inspection reports and who inspected and which vendor it came from and reasons for scrap and days to repair, but it seemed like I was the only one that really looked at it.

Is there anything you can eliminate? You certainly have a lot of data, do you use it all?
My GM likes all the info possible. He will ask questions like, "What's our biggest issue?" I'll respond, "Contamination". He turns around saying, "I want to know the biggest cause of the contamination, who is responsible the most for causing it, and on which line as well.

He always wants to view information from all sides.

:bonk:
 
A

Atom_Ant

#6
Nikki,

Our CEO sounds a lot like your boss. The only thing I would suggest is to try to remove any manual steps from your calculation. If you have a newer version of Excel available, you can do a lot with pivot tables and custom filters (even if you don't, you can do a lot of the same with formulas, but they get very complex).

By having filters that can switch off and on, you can answer a lot of the questions you mentioned with just a few clicks (and have pretty charts that update automatically to make the bosses go "ooooooh aaaaah")

(To prevent forum spamming, to be able to post links or images your post count must be 10 or greater. You currently have 9 posts.)
 
B

buzzjaw

#8
Highlight the first row and select Data, Filter (or Autofilter as I think it was prior to Office 2007). This will allow you to easily generate lists of specific issues (ie those raised in R&D and corrected in the month of May). To count entries use the count display in the status bar at the bottom of the application window. If you know what information you need to regularly produce you could create formulae to auto sum / count (investigate the countif function). To make formulae dynamic investigate Data Validation. If you are feeling ambitious you could automate reporting using Excel's VBA functionality, but this will take quite a bit of training if you aren't familiar with programming. I hope this is helpful.
 
J

JAltmann

#9
My GM likes all the info possible. He will ask questions like, "What's our biggest issue?" I'll respond, "Contamination". He turns around saying, "I want to know the biggest cause of the contamination, who is responsible the most for causing it, and on which line as well.

He always wants to view information from all sides.

:bonk:
From what your saying it looks more like a pareto chart is perferable for your GM. From the data used to create that pareto chart you'll have the quantitative analysis to give your GM the information he requests without overloading them with excess data.

Most higher level managers do not have the time or patients to datamine everything. I would look into creating charts for the higher level managers. Also without knowing what your companies acceptable levels of scrap/rework are some of those values may not be a concern, while others may be frightening. I would filter out some of the insignificant values.

Also it looks like you have alot of reoccuring problems, this would suggest the RC/CA is not suffcient, or that your not applying it across all product lines/PN's.
 

NikkiQSM

Quite Involved in Discussions
#10
Also it looks like you have alot of reoccuring problems, this would suggest the RC/CA is not suffcient, or that your not applying it across all product lines/PN's.
Yes you are 100% correct. We have several reoccuring issues - which is why I am trying to catagorize everything. I just finished grouping all of 2012 rejections and am now starting with 2011.

My gut tells me that I really only need data analyzed as far back as 2010. Before 2010, I was also the QC Manager and had so many responsibilities that I could not properly focus on the issues and spent more time logging them into the spreadsheet than actually putting forth proper CA. The resources just werent there to get the job done the right way, frankly.

Now that I am focusing on our QMS 100% - (there is now an actual person taking care of day to day quality issues) - I can put forth the effort to improve our system.

The first step for me - is to analyze all this data.

Once complete - I plan on holding a meeting, quarterly, with all of quality personnel and personnel from Production. I am hoping these meetings will trigger some brainstorming for ways to fix these issues and to drastically reduce the number of NCMRs.
 
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