Incoming Inspection andIn-Process Quality inCostpoint Manufacturing ExecutionBilly Shumate, Principal Consultant, DeltekTe...
AgendaSUPPLY CHAIN QUALITY ASSURANCE        OVERVIEW        QUALITY REQUIREMENTS AND INSPECTION PLANNING        SUPPLIER Q...
Supply Chain Quality Assurance      OverviewMES’s Supplier Quality Assurance system enables a systematic anddynamic approa...
Quality requirements & Inspection      PlanningThe Inspection Planning provides tools to manage the definition ofinspectio...
Quality requirements & Inspection          Planning (cont)Inspection and verification specifications can be set at differe...
Inspection Item ClassAll Inspection Items have an assigned Class.Each Class has an associated Acceptance Quality Level (AQ...
Sampling Rules     The Sampling Rules define the Sample Plan and Severity Switching7             ©2012 Deltek, Inc. All R...
Sampling PlansThe Sample Sizes logic is included in the Sampling Plans
Switching LogicThe Switching Logic changes the Sampling Rule Type based on the inspectionresults.For example: The Sampling...
Inspection Plans Inspection                         Check-List   Steps                               StepsReceiving       ...
Inspection StepsInspection Steps are place holders for inspection items defined in theinspection definition.Inspection ste...
Checklist StepsBoolean Yes/No questions.Documentation gathering through attachments.
Checklist WorkflowAllows workflow through the checklist process based upon thequestion results.
Inspection DefinitionsContainer of all the inspection items required for inspection.Can be created at three different leve...
Inspection Definitions
Inspection Item    Contains 4 elements of information
Inspection Item StepsSteps are assigned to inspection items.Steps are inspection points within an inspection process. Insp...
SubordinatesInspection Items can be identified as Master or Subordinate.If a Master Inspection Item is rejected then all o...
Requirement GroupsConsist of a grouping of inspection items that can be applied to parts orsuppliers.Process requirement, ...
Inspection Planning to Execution
Dispatch ListWhen an inspector logs on, all of the relevant open purchase ordersappear in the inspector-associated dispatc...
Inspection Orders –     ExecutionAll requirements are viewable by the inspector, includingspecification limits, criteria a...
First Article Inspection (cont)When purchase orders contain open FAI or FAI delta requirements, the systemflags the next i...
Supplier Quality CorrectionProcesses provide mechanisms for analyzing quality performance.Responding to discrepancies disc...
Discrepancy Flow
Creating a Discrepancy
Creating a Discrepancy
Discrepancies (cont)The disposition, review and approval workflow is configured tohandle complex routing requirements for ...
Quality HoldsHolds prevent any further work from being done on an inspection order.Visibility of holds is never lost throu...
Supplier Quality Analysis ToolsSupplier performance is tracked consistently
Supplier Quality Analysis ToolsSupplier performance is tracked consistently
Quality Management System OverviewFully manages all aspects of quality – from discovering and trackingdefects to identifyi...
Product and Process ControlProvides operators with easy-to-follow, enhanced work instructionsWork instructions can be as s...
Inspection InstructionsInspection instructions are incorporated into Work Plans,prescribe how to verify that each product ...
Data CollectionsEmbedded in instruction text blocks.Two types are used:Parameter - Record measurements and notations taken...
Work Instructions
Work Order Processing  Data Collection and Buy-Offs
Work Orders –    Creating a discrepancyInitiating a Discrepancy from a Buyoff.One of the most common ways to initiate a di...
Work Orders –     Creating a discrepancyInitiating a Discrepancy from a Work Order.Method used if there is not a buyoff in...
Types of DispositionsUse As Is: The part is OK to use as it is.Scrap: Part cannot be used.Return: The part cannot be used ...
Disposition InstructionsAppend to Operation: Adds an instruction to a specific operation/steps inthe original work order.A...
Liens                                   Authorize a Single Open WO             Authorize All Open WO’s for             Dis...
Quality MetricsReal-time reports and charts to view quality metrics, and drill down intoproblem areas for more details.Rea...
Quality Metrics (SPC “U” Chart)At the time a nonconformance is initiated, real time SPC data analysisis performed.
Trending Charts                  We can be proactive and                  initiate CA manually where we                  s...
Quality Historical Charts     We can be proactive and initiate     CA manually where we see     biggest opportunities     ...
Processing CA Requests       Or Request CA from Discrepancies       when action or recurrence are       obvious       Link...
8D Process for Root-Cause Corrective Action                    CA is configurable to support                    different ...
Form the Team    Everyone sees the CA on their task list.    Easy to know who is working on what.
Describe the Problem        Time to document the        Problem Description        As we investigate… we come        back ...
Affected Resources             Identify all affected/related             Parts, Tools, Machines,             Suppliers, Cu...
Attach Illustrations / DocumentsWe can also attach pictures    can also attach picturesor documentation   documentation
Contain the Problem   Until Corrective Action completed,   cannot ship product unless it has been   verified not to have a...
Containment ActionsOn Supplier side…  Containment Holds are automatically placed and prevent   shipment without special a...
Identify Root-Cause      The team should document      Investigation as they go      (not just at the end)
Investigation NotesEnvironment  Has anything changed in the last 2‐3 weeks? Nothing   apparent.People  Any new employees...
Investigation NotesMachines    Is equipment showing signs of aging wear and tear?    Was equipment properly calibrated? ...
Common Issue Templates                         Add common issue areas to                         templates to promote thor...
Supporting Documentation                              Attached meeting                              recordsDocument the re...
Action Item ClosureDocumented each Action Itemrecommended as part of theinvestigation.Identify responsible departmentand m...
Action Item VerificationIdentify who willverify Implementationfor each Action Item.
Verify EffectivenessOnce Effectiveness isverified, we can makethe new processespermanent.
Effectiveness VerificationThe CA team plans the timing and criteria for theeffectiveness verification.They can associate f...
Permanent Correction We can create New CA’s for Preventive Actions to prevent similar problems. Easily jump between linked...
Corrective Action Tasks                                                           Prioritize CA’s by Risk Score.          ...
Risk Score to prioritize CAsRisk-Score = (Likelihood-Rating-Score) x (Severity-Rating-Score) x (Detectability-Rating-Score...
Corrective and Preventive ActionClosed-loop corrective and preventive action process manages requests, action itemsand ver...
Thank You! billyshumate@deltek.com terryhowell@deltek.comGC-362: Work Plans and Manufacturing in Costpoint Manufacturing...
Upcoming SlideShare
Loading in …5
×

Deltek Insight 2012: Incoming Inspection and In-Process Quality in Costpoint Manufacturing Execution

1,764 views

Published on

Need incoming inspection? How about discrepancy reporting, non-conformances, or corrective action? In this session we will explore the how Costpoint MES fully manages all aspects of quality control from supplier delivery through the manufacturing process. Intermediate Level.

Published in: Technology
0 Comments
1 Like
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
1,764
On SlideShare
0
From Embeds
0
Number of Embeds
4
Actions
Shares
0
Downloads
40
Comments
0
Likes
1
Embeds 0
No embeds

No notes for slide
  • Workflows are user configurable.Classification can be used to determine corrective actions –Classification are pre-prepared and act to accumulate corrective actions in bundles for ease of identification and working.Disposition types for incoming inspection items include: TBD
  • All Supplier information is centralized in one screen including the Supplier Rating
  • Provides process control that ensures:Only operators with current skills and certifications perform jobs.Proper tools are used with current calibration dates.Complete and latest process documentation is used.Controlled change procedures for process instructions between engineering and manufacturing.
  • A discrepancy report is initiated if any of the characteristic data collections are rejected or out of limits.Discrepancies can be initiated during inspection or buyoff points in the work order. They can also be initiated for incidents independent from the current operation or work order.The disposition, review and approval workflow is configured to handle complex routing requirements for different types of discrepancies.Discrepancies are then automatically routed to the appropriate personnel. Discrepancy history is tied to each production unit or lot.A defective installed component or subassembly can be fixed in place or removed
  • have task groups, that would be MRO instructions types.
  • Alerts users of open items through liens. Liens act as virtual red tags on units with open discrepancies and rework.Special authorizations can be given to specific units with liens to continue work up to a certain point.Visibility of liens is never lost throughout the process, even when liens are inherited from installed components or subassemblies.
  • Containment demonstrates the value of the integration in SoluminaThese are the obvious benefits of tracking and correcting the problem……..
  • Deltek Insight 2012: Incoming Inspection and In-Process Quality in Costpoint Manufacturing Execution

    1. 1. Incoming Inspection andIn-Process Quality inCostpoint Manufacturing ExecutionBilly Shumate, Principal Consultant, DeltekTerry Howell, Principal Consultant, DeltekGC-355
    2. 2. AgendaSUPPLY CHAIN QUALITY ASSURANCE OVERVIEW QUALITY REQUIREMENTS AND INSPECTION PLANNING SUPPLIER QUALITY EXECUTION SUPPLIER QUALITY CORRECTIONQUALITY MANAGEMENT SYSTEM OVERVIEW MANUFACTURING PROCESS PLANNING MANUFACTURING PROCESS EXECUTION MANUFACTURING PROCESS QUALITYCORRECTIVE ACTION
    3. 3. Supply Chain Quality Assurance OverviewMES’s Supplier Quality Assurance system enables a systematic anddynamic approach to managing supplier quality.Provides a complete paperless system for defining, managing,communicating, and verifying product specifications and requirements.Offers a comprehensive quality-management solution for all discrete,complex manufacturers.
    4. 4. Quality requirements & Inspection PlanningThe Inspection Planning provides tools to manage the definition ofinspection and verification plans.Ensures compliance to specifications mandated by engineeringrequirements, contracts, and industry process standards.Supplies a central location for the authoring and maintenance ofinspection requirements for product-key characteristics including handling,labeling and packaging.Characteristic-measurement requirements include upper and lower speclimits, and sampling rules.
    5. 5. Quality requirements & Inspection Planning (cont)Inspection and verification specifications can be set at different levels for easier changemanagement:  Standard Requirement Group  Part Number Specific  Supplier/Part Number SpecificEach applicable level is added to form an Inspection OrderEach measurement or observation characteristic is assigned a sampling plan thatdetermines the frequency and sample size for each inspection. For example:  Characteristics considered critical may have 100 percent of all parts sampled and inspected.  Minor characteristics may have a smaller percentage of parts sampled and inspected.Based on recorded failure history, severity switching rules can include switching logic toautomatically switch to tighter or more relaxed sampling plans.Inspection Items (Characteristics) without any issues will gradually receive less attention,while trouble spots will receive more scrutiny.
    6. 6. Inspection Item ClassAll Inspection Items have an assigned Class.Each Class has an associated Acceptance Quality Level (AQL).The AQL values are used to determine the Inspection Item samplesize. CLASS AQL Critical 0% Major 1% Minor 4%
    7. 7. Sampling Rules  The Sampling Rules define the Sample Plan and Severity Switching7 ©2012 Deltek, Inc. All Rights Reserved
    8. 8. Sampling PlansThe Sample Sizes logic is included in the Sampling Plans
    9. 9. Switching LogicThe Switching Logic changes the Sampling Rule Type based on the inspectionresults.For example: The Sampling Rule Type may change from Normal to Full Inspection.The Switching Logic automatically adjusts the AQL based on the performance ofthe Inspection Item for a Supplier/Part.
    10. 10. Inspection Plans Inspection Check-List Steps StepsReceiving ReceivingInspection ChecklistOver Inspection Pre-Inspection ChecklistSpecialInspection Inspection Plan
    11. 11. Inspection StepsInspection Steps are place holders for inspection items defined in theinspection definition.Inspection steps names are user defined.
    12. 12. Checklist StepsBoolean Yes/No questions.Documentation gathering through attachments.
    13. 13. Checklist WorkflowAllows workflow through the checklist process based upon thequestion results.
    14. 14. Inspection DefinitionsContainer of all the inspection items required for inspection.Can be created at three different levels - part, supplier part, orrequirement group.The requirement group can be for anything: a process requirement, apart family, a commodity code or even a government requirement.Revision controlled and the system will default to the latest, completedrevision during inspection plan creation.Can contain attachments such as drawings, specifications, andmultimedia.
    15. 15. Inspection Definitions
    16. 16. Inspection Item Contains 4 elements of information
    17. 17. Inspection Item StepsSteps are assigned to inspection items.Steps are inspection points within an inspection process. Inspection steps areused to map inspection items to the inspection plan.Inspection items associated to an inspection step appear in the inspectionorder.
    18. 18. SubordinatesInspection Items can be identified as Master or Subordinate.If a Master Inspection Item is rejected then all of the Subordinate Inspection Itemsbecome mandatory.If the Master Inspection Item passes then the Subordinate Inspection Itemsbecome optional.
    19. 19. Requirement GroupsConsist of a grouping of inspection items that can be applied to parts orsuppliers.Process requirement, part family, and commodity code or governmentrequirement.Allows the attachment of documents required for a requirement group. Anexample would be: OHSA or ISO specifications.When an inspection order is created for an item in the group thecorresponding inspection items from the requirements group will also beincluded.When an inspection order is created for that supplier the correspondinginspection items from the group will also be included.
    20. 20. Inspection Planning to Execution
    21. 21. Dispatch ListWhen an inspector logs on, all of the relevant open purchase ordersappear in the inspector-associated dispatch list.
    22. 22. Inspection Orders – ExecutionAll requirements are viewable by the inspector, includingspecification limits, criteria and inspection method data.
    23. 23. First Article Inspection (cont)When purchase orders contain open FAI or FAI delta requirements, the systemflags the next inspection order accordingly.Ensures that all of the requirements for a FAI are compliant with AS9102requirements.FAI requirements must be completed before any units can be accepted.
    24. 24. Supplier Quality CorrectionProcesses provide mechanisms for analyzing quality performance.Responding to discrepancies discovered during inspection execution.Tracking continuous process improvement efforts as Corrective Actions withsuppliers.Respond to discrepancies discovered during inspection execution.Analyze quality performance.Track continuous process-improvement efforts with suppliers.
    25. 25. Discrepancy Flow
    26. 26. Creating a Discrepancy
    27. 27. Creating a Discrepancy
    28. 28. Discrepancies (cont)The disposition, review and approval workflow is configured tohandle complex routing requirements for different types ofdiscrepancies.Discrepancies are classified basedon defect, symptom, and cause types.A disposition can include instructionsto rework, repair, or scrap.
    29. 29. Quality HoldsHolds prevent any further work from being done on an inspection order.Visibility of holds is never lost throughout the process.
    30. 30. Supplier Quality Analysis ToolsSupplier performance is tracked consistently
    31. 31. Supplier Quality Analysis ToolsSupplier performance is tracked consistently
    32. 32. Quality Management System OverviewFully manages all aspects of quality – from discovering and trackingdefects to identifying and issuing the appropriate corrective actions.Identifies quality issues early in the process, reduces scrap and rework.Provides complete visibility into quality processes, accumulating thecomplete product genealogy for each unit in real time.Provides a full audit trail of the work process.By collecting these careful records, meets the strictest processmanagement and integrity requirements for multiple industries.
    33. 33. Product and Process ControlProvides operators with easy-to-follow, enhanced work instructionsWork instructions can be as simple as text or complex, including attachmentsand multimedia.Ensures quality standards by collecting electronic signatures, andincorporating inspection verification and statistical process control.Stores as-built product and device history on each unit by serial or lot number,including:  Work instructions  Data collection  Buyoff signatures  Discrepancies  Repairs  Materials  Components and subassemblies used
    34. 34. Inspection InstructionsInspection instructions are incorporated into Work Plans,prescribe how to verify that each product is built or serviced toengineering specifications.Inspection Instructions Include:  Inspection and test operations.  Data collection requirements with control limits.  Certified buyoff stamp requirements.
    35. 35. Data CollectionsEmbedded in instruction text blocks.Two types are used:Parameter - Record measurements and notations taken duringwork order execution, such as time, temperature, pressure, etc.Calculated - Automatically execute formulas using values enteredinto parameter data collections.
    36. 36. Work Instructions
    37. 37. Work Order Processing Data Collection and Buy-Offs
    38. 38. Work Orders – Creating a discrepancyInitiating a Discrepancy from a Buyoff.One of the most common ways to initiate a discrepancy.Normally discovered on the shop floor and the Quality inspector orShop Floor user will reject the buyoff and create a discrepancy.
    39. 39. Work Orders – Creating a discrepancyInitiating a Discrepancy from a Work Order.Method used if there is not a buyoff in an operation where you want to initiate adiscrepancy, or if a buyoff is not open at the time the discrepancy is found.
    40. 40. Types of DispositionsUse As Is: The part is OK to use as it is.Scrap: Part cannot be used.Return: The part cannot be used and is to be returned to its vendor.Rework: The part can be fixed and used.Repair: Can be repaired and reused. Determines how the part will beReplace Unit: Unit is scrapped and processed (disposition instructions) replaced by a new unit. Disposition instructions allowed for Rework and Repair
    41. 41. Disposition InstructionsAppend to Operation: Adds an instruction to a specific operation/steps inthe original work order.Alter Existing Instructions: Opens the original work order and puts it intoalteration.New Work Order: A new work order is created to process the discrepancyExisting Work Order: When approved new WOAn existing work order for the instructions released to the shop same part number that is put floor. into alteration. Rework and repair operations processed the same as planned work
    42. 42. Liens Authorize a Single Open WO Authorize All Open WO’s for Discrepancy Serial/Lot Authorize All Open WO’s for Higher Level Units12/11/2012 ©2012 Deltek, Inc. All Rights Reserved
    43. 43. Quality MetricsReal-time reports and charts to view quality metrics, and drill down intoproblem areas for more details.Real-time reporting feature measures:  Defects per Million Opportunities (DPMO)  Defective Parts Per Million (DPPM)  Six-Sigma and Defect Normalization. Continuous visibility of DPPM by Supplier/Part Real-time SPC indication of Out-Of-Control data collection measurements
    44. 44. Quality Metrics (SPC “U” Chart)At the time a nonconformance is initiated, real time SPC data analysisis performed.
    45. 45. Trending Charts We can be proactive and initiate CA manually where we see biggest opportunities Continuous Improvement (Kaizen)
    46. 46. Quality Historical Charts We can be proactive and initiate CA manually where we see biggest opportunities Continuous Improvement (Kaizen)46 ©2012 Deltek, Inc. All Rights Reserved
    47. 47. Processing CA Requests Or Request CA from Discrepancies when action or recurrence are obvious Link to Existing Or Create New CA It is ok to Deny CA Request… Not every Discrepancy calls for CA
    48. 48. 8D Process for Root-Cause Corrective Action CA is configurable to support different processes
    49. 49. Form the Team Everyone sees the CA on their task list. Easy to know who is working on what.
    50. 50. Describe the Problem Time to document the Problem Description As we investigate… we come back and can add more details.
    51. 51. Affected Resources Identify all affected/related Parts, Tools, Machines, Suppliers, Customers When first observed, frequency, etc.
    52. 52. Attach Illustrations / DocumentsWe can also attach pictures can also attach picturesor documentation documentation
    53. 53. Contain the Problem Until Corrective Action completed, cannot ship product unless it has been verified not to have a problem.
    54. 54. Containment ActionsOn Supplier side…  Containment Holds are automatically placed and prevent shipment without special authorization until CA completedOn Inventory side…  We can create Work Orders to Inspect inventory in stockOn Operations side…  We can add alerts where components are installed to check for condition until CA is completed.On the Customer side…  With integration to ERP, we can identify which units went to which customers and might need notification.
    55. 55. Identify Root-Cause The team should document Investigation as they go (not just at the end)
    56. 56. Investigation NotesEnvironment  Has anything changed in the last 2‐3 weeks? Nothing apparent.People  Any new employees involved? No  Has work rate changed recently? NoMethods  Are methods described properly? Usual for this type of work  Were prescribed methods followed? YesMachines…
    57. 57. Investigation NotesMachines  Is equipment showing signs of aging wear and tear?  Was equipment properly calibrated? Not sure  Why is this a suspect cause?  Because there is no record of what gauge was used  Investigated Tool Calibration in respective department  Found that some of the tools at the shop floor are out of calibration
    58. 58. Common Issue Templates Add common issue areas to templates to promote thorough investigationConfigure Templates toautomatically attach to each CA
    59. 59. Supporting Documentation Attached meeting recordsDocument the results of theInvestigationAttach Documents
    60. 60. Action Item ClosureDocumented each Action Itemrecommended as part of theinvestigation.Identify responsible departmentand manager. Manager mustacknowledge.
    61. 61. Action Item VerificationIdentify who willverify Implementationfor each Action Item.
    62. 62. Verify EffectivenessOnce Effectiveness isverified, we can makethe new processespermanent.
    63. 63. Effectiveness VerificationThe CA team plans the timing and criteria for theeffectiveness verification.They can associate files that contain verificationinstructions.Finally a Corrective Action is deemed effective or non-effective
    64. 64. Permanent Correction We can create New CA’s for Preventive Actions to prevent similar problems. Easily jump between linked CA’s.
    65. 65. Corrective Action Tasks Prioritize CA’s by Risk Score. Evidence of compliance for AS9100, Risk Management65 12/11/2012 ©2012 Deltek, Inc. All Rights Reserved
    66. 66. Risk Score to prioritize CAsRisk-Score = (Likelihood-Rating-Score) x (Severity-Rating-Score) x (Detectability-Rating-Score)Severity is based on a scale from Tolerable to Intolerable based on impact to Safety, Product Quality/Mission Assurance, and Schedule Severity-Likelihood- Likelihood- Rating- Detectability-Rating-Desc Rating-Score Severity-Rating-Desc Score Detectability-Rating-Desc Rating-Score Untolerable - no work around and highEvery Unit 5 impact or safety issue 5 Integrated Testing Required 5Every Day 4 Painful level of rework or work around 4 Destructive Testing Required 4 Significant impact toEvery 1-2 Weeks 3 schedule/mission/cost 3 Unit Testing Required 3Every 1-2 Months 2 Tolerable level of rework 2 Measurement Required 2Rare 1 Tolerable workaround 1 Visual Inspection 1 The CA list prioritized by Risk Score can be used as part of evidence of compliance with AS9100 Clause 7.1.2. Risk Management.
    67. 67. Corrective and Preventive ActionClosed-loop corrective and preventive action process manages requests, action itemsand verifications.Can be initiated from discrepancies or corrective action requests.Several requests can be linked to a single corrective action.Requests are created to track internally or externally initiated issues, such asrecurring defects or customer satisfaction concerns.Each corrective action is coordinated by a facilitator, who follows up on action itemsuntil a resolution is reached.Includes a root-cause corrective action feature that determines the cause of anonconformance and implements a corrective action to prevent it from reoccurring.To ensure non-conformances and corrective actions are properly identified, the 8Dproblem solving process is used.
    68. 68. Thank You! billyshumate@deltek.com terryhowell@deltek.comGC-362: Work Plans and Manufacturing in Costpoint Manufacturing ExecutionWed October 1704:30 PM -05:30 PM CDTLocation: Presidential Ballroom BThu October 1811:00 AM -12:00 PM CDTLocation: Lincoln AGC-358: The Future of Materials Management and Project ManufacturingWed October 1703:15 PM -04:15 PM CDTLocation: Presidential Ballroom D

    ×