Quality Assurance Lean Presentation September 2013

Last Years Outstanding Actions• Approved Suppliers List – Increase usefulness:

Purchasing Manager is responsible for this process and QA provide an auditing and guidance role.

• Benefit: A more productive method of working.• Work/Manufacture Instructions not current:

Current files updated, old files archived.• Benefit: Files are easier to find.• ‘Our Hub’: ATs project, which had it’s benefits

has had to be shelved due to the amount of time which would need to be put into the upkeep and maintenance of it.

FSC & ISO Updates

• Over 29 Procedure changes.• New procedure for installations added.• FSC Procedures added to procedures.• Quality manual updated/up issued.• FSC Test audit carried out by John

Freeman, issues raised and these are being dealt with.

• JH now a trained auditor, so back to three auditors on-site: MM, AW, JH.

Estee Lauder Improvements

• Implementation of Bar Code and Carton Label Check File.

• Implementation of Document Flip File.• Improved lighting over benches.• Supervisors & Team Leaders are also now

carrying out spot-checks to enable us to QC a larger percentage of our production.

• Potential to roll-out this or a similar quality package on other projects.

Estee Lauder Improvement Proposals

• Load-Up Sheets: Possibly structure?• Carton Labels: Improve checks at origin.• Euro Code: Continued confusion and rework of

carton labels. Anticipated production date to be input at creation.

• Client 1st Offs: Very often we are still manufacturing these parts when the units should be ready for presentation. Find ways to improve.

• Benefit: Eliminate the need to re-work pallets of goods.

• Benefit: Raise our image with the client.

New Inspection Report Layout

• Modified layout removed, parameters & Notes.

• Added Description of issues and comments & photographs.

• These changes will make reporting issues better, especially if the report is sent to a sub-contractor.

New Inspection Report

New Assembly First off Report

• More relevant information.

• More fields added, e.g. Installations, manufacturing issues.

• Easier to complete.

• Easier to read.

• Assembly aids section, non structured parts.

Old Version Assembly Report

New Version

Assembly First Off Summary Sheet

Assembly First Off Summary Sheet

• Central location for Design to access information.

• All columns are filtered to allow for search by specific criteria.

• Allows Designers to compare multiple Report results at-a-glance.

• Hyperlink to full list of First Off Reports.• Benefit: An aid for Design to view pros & cons of

a particular style of unit, easily.

SEAWARDClare Hal 104 End of Line Electrical tester

• Due to one of the SPS Lighting tester LG3301 has gone out of calibration and would have cost £715 to repair.

• The new tester has many advantages, than the old Clares testers.• Advantages• Smaller, easier to transport.• Large clear full graphic display.• Internal memory, about 6000 tests can be stored.• Power consumption reading.• Printer can be purchased with tester; eliminating compatibility issues with off the shelf

printers.• As we do not flash testing any more, we do not require a switch cable any more. Only

an earth prob. • Data can be down load to a laptop and stored, certificate can be printed off• Labels are more robust than the current labels we use; they use thermal transfer

process and eliminate the possibility of fade and tear resistant.• We may be able to transfer information from the laptop via wifi to another PC.• Pass word set/ security no keys.• Customers name could be added to test.• Kesslers name could be added to test results.

SEAWARDClare Hal 104 End of Line Electrical tester

• Disadvantages• Much more expensive than the SPS tester, SPS testers

about £3600.• Will only test 220-240V units, we would need to use a

voltage converter for 110v units; which we have.• Can only down load via cable transfer.• We would need a laptop for down loading of data.• Labels are more expensive £37.80 per roll(1000 labels)• We will still need to use terminal mains lead as the new

tester has only a plug socket.• Only has a 14 name capacity, e.g. tester identification.• Earth bond test .

SEAWARDClare Hal 104 End of Line Electrical tester

Earth Bond test Load

TestIR Test

SEAWARDClare Hal 104 End of Line Electrical tester

Tester mains socket

Earth and mains box

SEAWARDClare Hal 104 End of Line Electrical tester

Test results

Test certificate.

SEAWARDClare Hal 104 End of Line Electrical tester

• Cost of Tester & Accessories £5,794.90 Ex Vat.

• Delivery Date end of September.

• Training Date early October, Half day only.

Test information, pass and fail test shown.

Quality Meetings

• Greater emphasis on improvements.

• Departments to display a more pro-active approach to discussing, owning and solving their own quality issues.

• More departments to be included; Laser & Pcnc; Production Office and Technical will also now be covered.

Photograph Area• No adequate lighting,

very gloomy area.• No options for change of

background colour.• Suitable for large units.• Not as suitable for

smaller units.• Small units being

photographed in the Studio, but there is no designated area there either.

Photograph Area Proposal

• To create a photographic area with:

• Adequate, fixed lighting

• Suitable for large and small units

• Changeable background colours

• Benefit: Better quality photos, to showcase our units. A well set-up area will mean a speedier process.

L’Oreal

GA Si Launch TOD

09-7388001FS

C3

05.08.2013

Client:

Job:

Job No:

Date:

L’Oreal

Xmas 2013 GA Display

09-7356801FS

C3

06.08.2013

Client:

Job:

Job No:

Date:

Works Instructions

• Update existing instructions, remove extrusion process and add to VacForming dept.

• Write new instructions, create a work instructions called Plastics Processing Dept.

• Liaise with department heads to capture all relevant information.

Card-Backed Graphics

Card-Backed Graphics• A full-length FSU graphic measures 1583mm, our guillotine has a

max stop of 1550mm.• A graphic which has shrunk, or been cut too small leaves us with

bare MDF which is unsightly and detracts from the overall effect of the unit.

• Proposal: Find a way to eliminate the gap.• Consider: changing how we design our FSUs, to enable us to

guillotine our own graphics (this would potentially give us an extra day or two of drying/shrinking time).

• Consider: Printing onto styrene v cost of marker pens/tape and time used to disguise gaps.

• Consider: Investing in a guillotine with a larger working area (this could then also be used to catch more overflow from the Pcnc).

• Benefit: Eliminate the extra work, time and cost of using marker pens. Improve the aesthetics of the unit.

‘Un-released Parts’

‘Un-released Parts’

• At risk of producing unusable parts, and having to absorb the cost.

• Proposal:• Marpacs to flag a part as ‘on-hold’ when

the w/o is scanned?• Investigate what Marpacs can offer in

terms of this.• Benefit: reduce the waste/cost of

producing incorrect parts.

New Internal Reject Note

• IRN generated via marpacs.

• Serial No generated by marpacs.

• IRN updated via marpacs.

• Much easier to produce statistical information.

• Much easier to read/understand.

• More tick boxes.

• Training to be give to all personnel that require it.

• Better for the environment-less waste.

• Much easier to update-via pc.

• Much easier to manage-better for ISO.

New Reject Note