Cost of Quality

• Instructions are complex and unclear (mostly text based) and cause my employees to make mistakes.
• It is so complicated to make a change to the process-instructions that they don't improve...mistakes thus get repeated
• It takes too long for quality problems to be identified and fixed so many parts are affected before we recognize and fix a problem.
• Engineering changes are too slow which increases cost of scrap, rework, and obsolescence.
• Quality tracking is done on paper which takes hordes of clerks and checkers.

Problem: Instructions are complex and unclear (mostly text based) and cause my employees to make mistakes.

Our studies have shown that over 50 percent of scrap and rework costs could have been avoided if the process had been properly executed. Unfortunately most process instructions cannot properly convey the message.

Solution:

Simple, intuitive instructions. Complex processes can be better explained with images, video and animations that walk you through the process.

Results:

Reduction of scrap and rework

Problem: It is so complicated to make a change to the process-instructions that they don't improve...mistakes thus get repeated.

In a conventional paper-based environment documentation is broken down into categories and assigned to various groups and departments. When something has to change, the information goes from in-box to out-box back and forth until the details of the change are understood. It can take months to process an engineering change on the shop floor.

Solution:

The people requesting, processing and approving the change must have instant access to the same information such as what is happening on the shop floor or in the field to warrant the change, What do we need to achieve in this change, what documents should be affected and what will they look like after the change. Linking everyone in this way breaks down the barriers and encourages Rapid and Continuous Improvement.

• Solumina ties everyone involved in the change with it's workflow managed document handling tools. Work procedures, CAD drawings and Solids, Instructions, Specifications are all linked together and accessible to the entire team for review, corrections and approval.
  
• The Workflow engine ensures that everyone involved in the change including customers and Vendors are electronically dialed-in using the Internet.

Results:

Fast and accurate propagation of changes to the shop.

Problem: It takes too long for quality problems to be identified and fixed so many parts are affected before we recognize and fix a problem.

In complex industries, when a problem is found with a process, procedure, policy or product it can take weeks and even months to react to the information and push through an appropriate change. Often by the time the change hits the floor many parts have already suffered the fate of the deficient process. This translates into multiple-count scrap and rework (a no-no).

Solution:

The shop floor instruction delivery process must allow for instant hold assignments on suspect orders and the ability to quickly "Red Line" the instructions or parts list to temporarily correct the problem while the Engineering Change is being processed. Once that Red Line is done, it must be possible to propagate that (those) change(s) automatically to other orders that crop up using the same process or parts.

• Solumina provides full authoring capability for "Red Lining" shop orders and propagating to se changes to other orders.

Results:

Errors are caught fast and corrected before Scrap and Rework pile up.

Problem: Engineering changes are too slow which increases cost of scrap, rework, and obsolescence.

In a conventional paper-based environment documentation is broken down into categories and assigned to various groups and departments. When something has to change, the information goes from in-box to out-box back and forth until the details of the change are understood. It can take months to process an engineering change on the shop floor.

Solution:

The people requesting, processing and approving the change must have instant access to the same information such as what is happening on the shop floor or in the field to warrant the change, What do we need to achieve in this change, what documents should be affected and what will they look like after the change. Linking everyone in this way breaks down the barriers and encourages Rapid and Continuous Improvement.

• Solumina ties everyone involved in the change with it's workflow managed document handling tools. Work procedures, CAD drawings and Solids, Instructions, Specifications are all linked together and accessible to the entire team for review, corrections and approval.
  
• The Workflow engine ensures that everyone involved in the change including customers and Vendors are electronically dialed-in using the Internet.

Results:

Fast and accurate propagation of changes to the shop.

Problem: Quality tracking is done on paper which takes hordes of clerks and checkers.

Since most of the quality/historical information gathered on the shop floor is done either on paper or in systems that aren't connected to each other, the accuracy of the data collected is most often suspect. As an example, aerospace manufacturers and aircraft maintenance facilities use dedicated people for the sole purpose of checking if all required signatures are present and if their appropriate stamps are shown. Others check to see if serial numbers have been written down. Few manufacturers in even highly regulated environment have time to check if the numbers recorder are even accurate which often leads to embarrassment and rework when the error is found (often by the customer).

Solution:

Data collections, sign-offs and serialization needs to be performed and validated in real time. If a signature lacks a certification currency or if a serial number is inaccurate or previously used, it needs to be highlighted to the employee at that time before that component is closed up and assembled or installed into something else.

• Solumina verifies all electronic signatures for valid certifications and authority in real time.
  
• Solumina can validate tool IDs and ensure that the correct tool was used with an adequate Calibration status.
  
• Solumina verifies serial numbers against your inventory files to ensure the right part made it on the unit being worked on.

Results:

• The data is right the first time!
• A complete as-built/as-maintained database is available at your fingertips when required