Final suggestion of an analysis to my last company and design of a new way of thinking about quality system that must migrate from a clasical quality system to a new one directed to assure quality and productivity using lean manufacturing tools.

1. Actual QS System and thefuture Actual processdesign Futureprocessdesign

2. Pros and cons of actual Processdesign PROS CONS

3. Actual QS Systemdesignisbasedonproductbutnot in process Duetothis, ouractivities are focusedonreactonproblemsinstead of preventpotentialpoblems. Thedesign of preventivetoolssuch as PFMEA are notdesigned in ordertopreventpotential causes, theyhaveanauditmeaningthereforetheirtraductioninto shop floor are notwelldefined. Thatisthereasonforwefindrandompoblems in shop floor and in customerrelatedissues. Eachonewihoutanapparent cause butthey are relatedtothesameitem: wehave a processdesign in product and not in theprocessiself.

4. Howtomakechanges? Weneed redefine activities in ordertomakeeasyidentifyimprovementsareas, measurevalues and make a preventivecompanyinstead of reactive company Aprox 3 months

5. Howto redefine QS System? Learn actual QS system and eliminateactivitiesthatdoesnotgeneratevalueforexampleexcesive control (registers), redefine activitiesusing 7 muda analysis, and planninglearnmanufacturingplanning. Increasesystem inputs in new projects, engineering & qualityareas. Make a stronganalysis in outputs forexamplecustomercomplaints, deliveryobjectives (status), managmentreviewetc. Increasepersonnelempowerment

6. Lean Methodology Theway of thinking Thebasis 7 wastes (muda)

7. Startwiththebasis!

8. Thegoal: Ourcompanycan becappablefordetect and correctissueslike…

9. QualityOrganization Chart

11. Addedvalueactivities

12. Initiateactiontopreventtheoccurrence of any non conformances

13. Train & supervise appropiatedstaffingtomaintainqualityassurance

14. Respondtocustomerrequest in a timely and throughfashion

15. Monitor existingvendorsupply bases toinsurethatguidelines and specifications are met.

16. Supportengineeringeffortstodevelop, maintain and improveproductstomeetcustomerexpectations

17. Makeroot cause analysis

18. Has theauthorityto stop theproductionprocessif a safety orqualityconcernisnoticed

19. Has final authorityoverdispositiontoacceptanceorrejectedprocess & product

20. Lead qualityaudits.

21. Developcontinuousimprovementactivitiesusing lean manufacturingtools

22. Implement lean manufacturingtechniques

23. Deployactionsfocusedto reduce non valueactivities

24. Proposeactivitiesrelatedtoself control in process

25. Leads 5 s activities in hisarea

26. PromoteJidokaconceptsintoprocess

27. Define qualitycriteriaforproducts.

28. Coachprocessleadersfor lean manufacturingtechniquesimplementation

31. Addedvalueactivities

32. Develop and maintain a qualitysystems manual whichwillassureproduct and processcompliance

33. Coordinate and performqualitysystemauditstoadheretoall TS 16949 guidelines

34. Workwith new projects in ordertoassurecompliancetocustomerspecifications and requirements (PFMEA, PPAP, Control plan, etc)

35. Developmanufacturing manual accordingto TQM activities and relate thisactivitiesintoquality manual and actual Qualitysystem

37. Addedvalueactivities

38. Maintain and managelaboratoryequipment and fixtures

39. Manage R&R studies

40. DevelopCpkstudies

41. He willmake dimensional analysis and functionaltests

42. Carryout MFR test

43. Develop dimensional lay outprogram and executethem

44. Manageannualraw material test (requalification)

45. Developinitialsamplesreport and pointoutdifferences

46. Train qualitypersonnel in use of laboratoryequipment

48. Addedvalueactivities

49. Approveorrejectraw material & components inabsence of shipping supervisor

50. Make D test

51. Makeproductaudits

52. Folowing 8D open issues in production line

53. Registerfailures & approval data duringtheirinspection

54. Checkapproveddeviationssheet and verifytheirapplication in shoopfloor

55. Describedailyactivities in log book

56. Stop production line whendetects non conforming material

57. Execute machine processaudits and presentsresults

58. Followactions of machine processaudits

59. Approveinjection & assamblyprocessaccordingtoprocesschecklist

61. Addedvalueactivities

62. Newiepersonneltrainer

63. NewiepersonnelCompetenceevaluation

64. Otheractivities are same as qualityprocess inspector

65. Redefine activities