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presented by:
Brian Harvey Quality Manager – Clamonta Ltd
asmall
businessperspective &
9103presented to:
IAQG
agenda
• morning presentation– how a small business implemented
9103
• afternoon break out session– 9102 FAI process improvement
software
presented by:
Brian Harvey
located: Nuneaton, Warwickshire, UKemployees: 45sales: £4.25 millionestablished: 1960manufactures: components & assembliesapprovals: 9100 & NADCAP
continuous improvement
strategy
processimprovement
chartingkaizen EFQM5s
9103 barriers
1. middle management2. cost/benefit3. communication4. training5. data collection method6. product type
?
process improvement charts:individuals X
UCLx
LCLx
1. measurement data
2. equipment3. batch/job
number4. date & time5. location
1. text message or e-mail to process owner
2. cause & corrective action from chart ownerdiscovering the
truth about our processes
andtraining our people at the
same time
Real Time Process Improvement
facilities layout
office
turncell
millcell
grindcell
ndt
lockplatecell
heattreat
runnersrepeater& strangers
repeater & strangers
• 300 parts/ month
• batch sizes 1 to 24 off
• repeat 1 to 5 years
January 2003
September 2003
repeaters & strangers results
failure
appraisal
prevention
failure
appraisal
prevention
qualitycosts
before after
1 person running 2 CNC lathes3 month trial40 parts numbers4000+ measurements
4 non-conforming parts
WITH
4 people running 8 CNC lathesaverage 40 part numbers each
200+ non-conforming parts
WITHOUT
runners
• 55 part numbers
• 65000 parts / year
• batch sizes 100+
• repeat 1 to 4 months
Cpk improvements
• milling fixtures problems < 1.33 Cpk
• our team solved that problem• now >1.66 Cpk
(parts per million)
runners ‘cell’ results in <5 years
• <½ resource• 35% more product• in-process inspection only • zero delivered non-conformance• <£4K internal scrap (£950K
turnover)
9103 savings
1. reduced non-conformance2. improved root cause problem
resolution3. increased efficiency4. improved flow
Clamonta LtdWhitacre Road
NuneatonWarwickshire
CV11 6BXUnited Kingdom
Tel:+44 (0) 24 76382447 / 76370307Fax:+44 (0) 24 [email protected]
www.clamonta.co.uk
thank youhand overto Delta -
Dave Wentworth