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Unified Doc Control and Shop Floor Quality Control

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By having your document control and shop floor quality control systems tied together at the data level, this assures all your quality efforts are operating under the same best practices and use the …

By having your document control and shop floor quality control systems tied together at the data level, this assures all your quality efforts are operating under the same best practices and use the same data. No problems will be caused due to duplication of effort or data errors. And by having one set of master data - including ERP - you can operate fully within your QMS guidelines.

Read full description of this webinar on the IBS America, Inc. Blog:

http://info.ibs-us.com/blog/bid/37826/Webinar-How-to-Merge-Document-Control-and-Shop-Floor-Quality-Control

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  • 1. IBS: Unified Document Control and Shop Floor Quality Control
    August 2011
    IBS America
    T H E P R O D U C T I V I T Y A D V A N T A G E
  • 2. Agenda
    The Case for Unified Quality
    CompliantPro
    QSYS
    IBS
    Question and Answer
  • 3. Unified Quality Management
    Document Based and Transaction Based
    • Document Based and Transaction Based
    • 4. Why do you need both?
    • 5. How do they work together?
    • 6. What kinds of functionality do they provide?
    • 7. How does it support Your Business Initiatives?
    © IBS AG Slide 3
  • 8. CAD
    UNSTRUCTURED DATA
    SSO
    • Machines
    Master
    Data
    User
    STRUCTURED DATA
    QUALITY BUS
    QSYS
    ERP
  • 11. What Kinds of Functionality do they Provide?
    • Document Control and Change Management
    • 12. Compliance ISO / Gov. / Regulating Body
    • 13. Real Time Inspections and Analysis
    • 14. Advanced Quality Planning/FMEA
    • 15. Complaint Management
    • 16. Scheduling and Execution Management
    • 17. Training Management
    • 18. Corrective Action Management
    • 19. Calibration Management
    • 20. Laboratory Management
    • 21. Plan – Do – Check – Act
    © IBS AG Slide 5
  • 22. How Do We Support the Organizations Initiatives?
    Quality Systems act
    like levers to reduce cost
    Higher Quality =
    Higher Market Share
    Compliance To Standards
    Records, Controls
    Schedules, Training
    and Verifiable Proof
    © IBS AG Slide 6
  • 23. Operational Management
    • Integrate engineering, production, quality
    • 24. Increase productivity
    • 25. Reduce scrap and rework
    • 26. Lower Costs
    • 27. Establish Plans, Controls and Train
    • 28. ISO & Governmental
    © IBS AG Slide 7
  • 29. Users
    • Do Jobs Correctly
    • 30. Efficiency
    • 31. Know How
    • 32. Safety
    • 33. Input / Feedback
    • 34. Work Instructions
    • 35. Expertise/Training Profile
    • 36. Best Practices
    • 37. Videos / Graphics / Pictures
    • 38. Handling and Safety Info, especially in case of an incident
    • 39. Corrective and Preventative action requests
  • Agenda
    Agenda and Introduction
    Customer Case Studies / Benefit Analysis
    Solutions Overview
    Company Overview
    Discussion / Goals
  • 40. The Case for Interactive Shop Floor Quality
    • Solve Quality Issues Early in the Cycle: How?
    • 41. Design and Plan for reliability, quality $$$$
    • 42. Verify Supplier Quality
    • 43. Monitor Production Quality
    • 44. Use Proven Improvement Processes Continuously:
    • 45. SPC
    • 46. CAPA
    • 47. FMEA
    • 48. PDCA
    © IBS AG Slide 10
  • 49. IBS Quality ManagementSolution: PDCA-cycle
    Action Management
    FMEA
    Control Plan
    Flowchart
    Project
    Management
    Problem Solving Process
    Audit Management
    Inspection Planning
    Incoming Goods
    SPC
    Production
    Quality Control Panel
    Supplier Assessment
    Outgoing Goods
  • 50. IBS Quality Execution ManagementSolution: PDCA-cycle
    Action
    Management
    Order Management
    Resource Planning
    Problem Solving Process
    Audit Management
    Fine planning
    Process Overview /
    Online-Visualization
    Paperless
    Repair
    KPI (OEE, FPY)
    Analysing (PAA, CPK)
    MDA
    ODA
    © IBS AG Slide 12
  • 51. IBS Traceability solutions for product and process traceability
    Purchased Parts
    Transport
    Traceability
    KPI‘s
    Cockpit
    Standard Components
    Standard Assembly Groups
    © IBS AG Slide 13
  • 52. CompliantPro at-a-Glance
    CAPA
    FDA
    Compliance
    CAPA
    FDA
    Compliance
    Training &
    Qualifications
    Enterprise
    Risk
    Management
    Training &
    Qualifications
    Risk
    Management
    & SOX
    Audits &
    Assessments
    Document
    Management
    Environmental
    Health &
    Safety
    Document
    Management
    Health & Safety
    Supplier
    Management
    Supplier
    Management
    Environmental
    Customer
    Management
    Inspection
    Management ,
    Nonconformance,
    & SPC
    Customer
    Management
    APQP
    (FMEA/Control
    Plan/PPAP)
    Prüfmittel-
    management
    Equipment
    Maintenance
    & Calibration
    Reporting
    Prüfmittel-
    management
    Equipment
    Maintenance
    & Calibration
  • 53. Slide 15
    Document Control
    User’s Administrator Sets Up the:
    • Different Document Categories
    • 54. Document Templates for each Category
    • 55. List of who can create Documents
    • 56. Document Numbering Scheme
    • 57. Review, Approval and Obsolescence Workflows
    • 58. Management Escalation Procedure
    • 59. Document Release Date
    • 60. Restriction of Access to Specific Documents
  • Slide 16
    Integrated Training & Qualification
    • Notifies each employee that they need training.
    • 61. Links to updated documents and changing course requirements.
    • 62. Advises of any missed deadlines.
    • 63. Alerts manager when employees are deficient/ create list.
    • 64. Meets regulatory requirements for monitoring employee qualifications.
    • 65. Prevents oversights.
    • 66. Automates the monitoring function.
    • 67. Prevents assignment of unqualified employees
    • 68. Automated escalations.
  • Training & Qualification Features
    Integrated with Document Control in Order to Reflect Changes to all Document Control Documents plus:
    Qualification Definitions
    Courses
    Certifications
    On-the-Job Training, etc.
    Multiple levels of security for:
    Managers
    Supervisors
    Trainers
    HR Managers
    Multiple Sets of Job Requirements per Employee to Accommodate:
    Multiple Job Responsibilities
    Corporate, Departmental, or Plant-Specific Training Requirements
    Accommodates Multiple Types of Training Qualification Options:
    Course Completion Only
    Pass/Fail
    Pass/Fail with Effectiveness Review
    Waived
    Expired
    Optional Self-Acknowledgement Completion
  • 69. Slide 18
    Corrective Actions & Preventive Actions Modules
  • 70. Slide 19
    Corrective and Preventative Actions
    • Configure multiple types of CARs or PARs to meet your unique requirements.
    • 71. Allow a leader to assign a “team” to manage Containment and Resolution responses.
    • 72. Elect to follow an “8D” or “7Step” procedure model, or Configure your own specific workflow for CAR resolution.
    • 73. Allow different methods of CAR creation
  • 74.
  • 75. Agenda
    Agenda and Introduction
    Customer Case Studies / Benefit Analysis
    Solution Overview
    Company Overview
    Questions?
  • 76. IBS America, Inc.
    • Group with 5 companies
    • 77. Germany, USA, Lithuania plus
    China
    • Publicly traded since 2000
    • 78. Revenue 2008: ~ $30 million
    • 79. Founded in 1982
    • 80. Today about 180 employees
    • 81. Supporting over 4000 customer installations globally (spanning over 50 countries and 5 continents)
  • Key Competences & Positioning
    InnovativeSoftware
    Solutions
    Services
    Integration with
    corporateIT-Systems
    • Industry independent Process consulting
    • 82. Implementation
    • 83. Training
    • 84. Project Management
    Directors
    MIS
    ERP
    MES
    Company mgmt.
    Process control
    Data flow
    Machine
    control
    Production
    Maintenance
    Operation
    Implementation
  • 85. IBS Customers Save Money
    The Cost of Quality as % of Revenue
    Source: Aberdeen Group 2009
    IBS customers achieve substantial cost reductions
    with better than average performance (e.g. first pass yields, on time shipments).
  • 86. Agenda
    Agenda and Introduction
    Customer Case Studies / Benefit Analysis
    Solution Overview
    Company Overview
    Questions?
  • 87. Thank You!
    “Merging Document Control with Shop Floor Quality Control”
    Presenter: Tim Gamble
    Email: tim.gamble@ibs-ag.com
    Phone: 1 (781)-862-9002 x137
    Read the IBS Blog for more quality resources, whitepapers, articles, and webinars: www.info.ibs-us.com
    Follow Us on Twitter: @IBSAmerica