This newsletter provides information about Nadcap audits and common nonconformances. It discusses the Nadcap Welding Task Group and most frequent nonconformances found during welding audits, such as a lack of documented procedure to control electrodes and non-compliance with pre-weld preparation procedures. The newsletter aims to help suppliers strengthen process control to avoid these common pitfalls and better prepare for Nadcap audits. It also provides an overview of the second part of a two-part article on root cause analysis methodology according to Nadcap standards.
Process improvement techniques and its applicability in pharma mfg an overviewVikalpNagori1
The document discusses various process improvement techniques and their applicability in pharmaceutical manufacturing. It describes techniques like Six Sigma, Lean Manufacturing, Lean Six Sigma, Total Quality Management, Toyota Production System/Just-in-Time, Theory of Constraints, and tools like FMEA and PDCA cycle. These techniques aim to reduce defects, waste, variation and improve efficiency in pharmaceutical operations throughout the product lifecycle from development to manufacturing to distribution. The document emphasizes applying these techniques and tools at various stages like development, manufacturing, and lifecycle management to ensure defect-free quality and efficient processes.
Detailed insight of Strategy Deployment in an Organization encompassing: Vision, Mission & Quality Policy, Goals and Objectives & its importance, SMART Objectives, Target & Requirement of Objectives in ISO 9001:2015 Standard
We can’t keep doing what we have always done and expect different results.
70% of maintenance and reliability projects fail due to poor execution. Learn why and what you can do to improve your odds.
This is a short and easy read focused on discipline of execution.
This document discusses process improvement techniques. It provides an overview of commonly used process improvement methodologies like DRIVE, Process Mapping, DMAIC, SPC, and Simulation. Process improvement techniques like Lean and Six Sigma are increasingly being used to redesign and optimize processes. These techniques require engagement from employees to achieve better results and ensure practices are embedded within an organization. Knowledge transfer partnerships can provide a cost-effective alternative to external consultants for process improvement projects. They allow access to university expertise and support for developing and delivering improvement projects. Some example cases and additional details on techniques are available in the listed sources.
This document provides an overview of 8D problem solving methodology. It describes the 8D process as a systematic approach to solving critical problems in production. The 8 steps include forming a problem solving team, describing the problem, developing interim containment actions, determining the root cause, developing permanent corrective actions, implementing and verifying the actions, preventing recurrences, and closing out the project. Benefits of 8D include improved team problem solving skills and understanding of root cause analysis. The document also discusses common shortfalls in problem solving and how a consulting firm can help clients apply the 8D methodology.
This document discusses various quality improvement principles, methods, and tools. It covers the following key points:
1. Quality improvement requires high intention, effort, direction, and execution. Data should be used to make decisions and assess whether improvements are successful.
2. Common quality improvement methods discussed are Failure Mode and Effects Analysis (FMEA) for proactive risk assessment, Lean thinking to eliminate waste and streamline processes, and the Plan-Do-Check-Act (PDCA) cycle for reactive problem solving projects.
3. When selecting a quality improvement project, factors to consider include the problem's significance, size, repetition, potential impact, and urgency. The document provides an example project selection table.
This document discusses quality management tools including PDCA-CQI, DMAIC, and DMADV. PDCA-CQI refers to the plan-do-check-act cycle for continuous quality improvement. DMAIC is a five-phase process for improving processes, and DMADV is a five-phase process for designing products and processes. Seven basic quality tools are then defined: cause-and-effect diagrams, control charts, check sheets, histograms, Pareto charts, scatter diagrams, and flow charts. Management and planning tools are also briefly mentioned. The presentation aims to explain these tools to support complex decision making and continuous improvement efforts.
This document outlines a Six Sigma project to optimize an article library. The project aims to improve article trustworthiness by 80%, discard 60% of duplicate and out-of-date articles, decrease article retrieval time to 8 minutes or less, decrease costs by 20%, and increase customer satisfaction by 35%. Baseline data found the average article retrieval time was 11.6 minutes with a process sigma level of 3.195. Analysis identified duplicate articles, out-of-date articles, and untrustworthy articles as causes of long retrieval times. Improvement strategies included digitizing articles, adding expiration dates, and verifying article trustworthiness to comply with specifications.
Process improvement techniques and its applicability in pharma mfg an overviewVikalpNagori1
The document discusses various process improvement techniques and their applicability in pharmaceutical manufacturing. It describes techniques like Six Sigma, Lean Manufacturing, Lean Six Sigma, Total Quality Management, Toyota Production System/Just-in-Time, Theory of Constraints, and tools like FMEA and PDCA cycle. These techniques aim to reduce defects, waste, variation and improve efficiency in pharmaceutical operations throughout the product lifecycle from development to manufacturing to distribution. The document emphasizes applying these techniques and tools at various stages like development, manufacturing, and lifecycle management to ensure defect-free quality and efficient processes.
Detailed insight of Strategy Deployment in an Organization encompassing: Vision, Mission & Quality Policy, Goals and Objectives & its importance, SMART Objectives, Target & Requirement of Objectives in ISO 9001:2015 Standard
We can’t keep doing what we have always done and expect different results.
70% of maintenance and reliability projects fail due to poor execution. Learn why and what you can do to improve your odds.
This is a short and easy read focused on discipline of execution.
This document discusses process improvement techniques. It provides an overview of commonly used process improvement methodologies like DRIVE, Process Mapping, DMAIC, SPC, and Simulation. Process improvement techniques like Lean and Six Sigma are increasingly being used to redesign and optimize processes. These techniques require engagement from employees to achieve better results and ensure practices are embedded within an organization. Knowledge transfer partnerships can provide a cost-effective alternative to external consultants for process improvement projects. They allow access to university expertise and support for developing and delivering improvement projects. Some example cases and additional details on techniques are available in the listed sources.
This document provides an overview of 8D problem solving methodology. It describes the 8D process as a systematic approach to solving critical problems in production. The 8 steps include forming a problem solving team, describing the problem, developing interim containment actions, determining the root cause, developing permanent corrective actions, implementing and verifying the actions, preventing recurrences, and closing out the project. Benefits of 8D include improved team problem solving skills and understanding of root cause analysis. The document also discusses common shortfalls in problem solving and how a consulting firm can help clients apply the 8D methodology.
This document discusses various quality improvement principles, methods, and tools. It covers the following key points:
1. Quality improvement requires high intention, effort, direction, and execution. Data should be used to make decisions and assess whether improvements are successful.
2. Common quality improvement methods discussed are Failure Mode and Effects Analysis (FMEA) for proactive risk assessment, Lean thinking to eliminate waste and streamline processes, and the Plan-Do-Check-Act (PDCA) cycle for reactive problem solving projects.
3. When selecting a quality improvement project, factors to consider include the problem's significance, size, repetition, potential impact, and urgency. The document provides an example project selection table.
This document discusses quality management tools including PDCA-CQI, DMAIC, and DMADV. PDCA-CQI refers to the plan-do-check-act cycle for continuous quality improvement. DMAIC is a five-phase process for improving processes, and DMADV is a five-phase process for designing products and processes. Seven basic quality tools are then defined: cause-and-effect diagrams, control charts, check sheets, histograms, Pareto charts, scatter diagrams, and flow charts. Management and planning tools are also briefly mentioned. The presentation aims to explain these tools to support complex decision making and continuous improvement efforts.
This document outlines a Six Sigma project to optimize an article library. The project aims to improve article trustworthiness by 80%, discard 60% of duplicate and out-of-date articles, decrease article retrieval time to 8 minutes or less, decrease costs by 20%, and increase customer satisfaction by 35%. Baseline data found the average article retrieval time was 11.6 minutes with a process sigma level of 3.195. Analysis identified duplicate articles, out-of-date articles, and untrustworthy articles as causes of long retrieval times. Improvement strategies included digitizing articles, adding expiration dates, and verifying article trustworthiness to comply with specifications.
- The document discusses the origins and development of Lean manufacturing and Six Sigma processes at Toyota Motor Company in the 1950s as they struggled with limited resources. Engineers Taiichi Ohno and Shigeo Shingo developed the Toyota Production System (TPS) to reduce waste and increase efficiency.
- TPS and Six Sigma methodology focus on reducing defects and process variation to improve quality and efficiency. When implemented together as Lean Six Sigma, they provide a systematic approach to continuous process improvement.
- Lean Six Sigma can be applied to manufacturing and service industries to reduce waste and improve processes in order to increase customer satisfaction and cost savings. The document outlines a sample deployment plan to implement Lean Six Sigma at an organization.
The document outlines an agenda for a workshop on change management methodologies and approaches for successful IT-healthcare projects. The workshop will cover understanding change management, Prosci and CAP change management methodologies, the relationship between change management and project management, and real-life use cases from MOH hospitals. It will define change management and discuss states of change, reasons for managing change, and choices individuals can make at different stages of a change process to have positive or negative outcomes. The goal is to provide guidance on successful change management.
This document discusses the application of Lean Six Sigma (LSS) processes to improve drug discovery within AstraZeneca. It describes a LSS project conducted within the Discovery Drug Metabolism and Pharmacokinetics department. The project aimed to improve the process of gathering pharmacokinetic data for lead optimization projects within tighter timelines. Through defining, measuring, analyzing, improving and controlling the process, the project identified inefficiencies and variability that could be addressed. Implementation of changes resulted in dramatic reductions in variability and turnaround times for providing pharmacokinetic data to meet project needs.
8D Training Material From VDiversify.com | 8D Training Material PDF Free Down...VDiversify
Note: Whoever is using this Training Material on their Website shall Link back to www.vdiversify.com as the Original Author...
The 8D (Eight Disciplines) approach is a robust and systematic problem-solving process or methodology, that is widely adopted in the manufacturing, process and other industries.
This 8D training material is completely free and can be used by any organization, professionals, engineers, trainers or teachers all over the world for teaching its employees or students.
The document discusses effective corrective action programs. It defines a corrective action program as a process that manages various inputs like non-conformances, audits, and complaints. It also manages resources to provide training on techniques like team problem solving. The ideal program applies a problem solving method like 8D across the organization and continuously improves by learning from results and implementing preventative actions.
1. Change management is crucial to the success of any CRM project as it focuses on addressing the behaviors, attitudes, and culture within an organization.
2. An effective change management plan involves formalizing the process, defining the program, establishing management structure, communicating to stakeholders, and involving people to create champions of change.
3. Key components of change management include understanding the business, people, process, and technology dimensions of change and having a plan to address each area.
ABOUT THE TRAINING PROGRAM :-
Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events. The practice of RCA is predicated on the belief that problems are best solved by attempting to address, correct or eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. By directing corrective measures at root causes, it is more probable that problem recurrence will be prevented.
DESIGNED FOR :-
Managers, Engineers, Supervisor and officers engaged in maintenance operation and engineering activities.
OBJECTIVE :-
At the end of the training program, participants will be able
- To gain a basic understanding of the problem solving and decision-making process and the applicable quality tools that support this process.
- To develop specific competencies to use the structured approach to problem solving and decision making and the supporting quality tools.
TRAINING PROGRAM COVERAGE :-
- Basic knowledge about RCA program.
- What are the RCA tools ?
- More about Why- Why analysis ?
- Videos and case studies on RCA
The document provides guidance for healthcare organizations to improve the patient experience through quality improvement projects. It outlines a three-phase process: planning, executing, and reflecting. The planning phase involves creating a "blueprint for success" which identifies the priority area, leadership team, aims, deliverables, scope, sponsor, and expectations. It emphasizes establishing effective multidisciplinary teams that include patients. The executing phase provides strategies, tools, and tips for implementing ideas. The reflecting phase involves analyzing current processes and identifying opportunities for change. The document aims to guide organizations through each step to achieve successful quality improvement.
The document discusses applying lean principles to business processes and administrative functions, not just manufacturing operations. It provides an overview of common constraints that arise from support areas like sales, purchasing, engineering, and accounting. These constraints can inhibit improvements achieved on the shop floor. The author advocates using tools like strategic alignment, process mapping, and value stream analysis to identify waste and constraints in business processes. Addressing these administrative constraints through techniques like standard work and visual management can help sustain lean initiatives and further reduce bottlenecks to operations.
The document provides an overview of key business improvement methodologies including Total Quality Management (TQM), Lean, and Six Sigma. It discusses the origins and key principles of each approach. TQM emerged from the Japanese quality evolution of the 1950-1980s and focuses on customer satisfaction through continuous improvement and employee involvement. Lean focuses on eliminating waste through flow and pull systems. Six Sigma aims for near perfect process performance through definition, measurement, analysis, improvement and control using statistical tools. The document also explores the integration of Lean and Six Sigma approaches.
The document discusses the 8D problem solving approach, which is an eight step method used to resolve chronic and recurring problems. It begins by explaining the 8 disciplines and when an 8D approach would be appropriate to use. It then describes each of the 8 steps in detail: 1) Team Formation, 2) Problem Description, 3) Containment Actions, 4) Developing Root Causes, 5) Developing Permanent Corrective Actions, 6) Implementing Permanent Corrective Actions, 7) Preventing Reoccurrences, and 8) Recognizing the Team. Key aspects of each step like necessary tools, checkpoints, and responsibilities are outlined. The document provides an in-depth explanation of applying the 8D method
This document provides an introduction to systematic problem solving using the 8D method. It discusses the purpose and content of the training, which is to teach participants a disciplined problem solving approach. The training schedule is outlined, which includes exercises to apply the 5 pillars of 5S: Sort, Set in Order, Shine, Standardize, and Sustain. Types of problems are defined, including sporadic versus chronic problems. The 8D problem solving model is introduced, which follows a plan-do-check-act cycle. Key aspects of systematic problem solving such as defining the problem, understanding root causes, using data and tools, and preventing recurrences are also outlined.
The document discusses using the DMAIC process for SEO projects. DMAIC is a structured problem-solving methodology originally developed by Motorola for process improvement. It stands for Define, Measure, Analyze, Improve, and Control. While originally used for manufacturing, DMAIC can also be applied to digital marketing projects by defining problems, measuring key metrics, analyzing data to determine root causes, improving processes, and controlling changes. The document provides details on carrying out each step of the DMAIC process for SEO projects.
This document provides an introduction to the Plan-Do-Study-Act (PDSA) cycle for quality improvement. It explains that PDSA cycles allow for testing changes on a small scale through iterative learning. Changes are implemented in controlled steps to identify problems early before full implementation. The document prompts the reader to think of an accreditation standard they want to improve and develop a PDSA cycle to test changes toward meeting that standard. It emphasizes that PDSA cycles incorporate documentation and data over time to support local learning and sharing of lessons with others.
This document discusses the 8D problem solving methodology used in the automotive industry. 8D stands for 8 disciplines or 8 steps and was introduced by Ford Motor Company in the late 1980s as a systemic problem solving approach. The 8 steps include establishing a team, defining the problem, implementing containment, identifying the root cause, choosing and verifying permanent corrective actions, implementing the actions, and preventing recurrence. Visualization techniques and a focus on facts are emphasized to support analyzing problems and identifying root causes. The goal of 8D is to stop issues from recurring through a disciplined process.
The document discusses the 8D problem solving process which consists of 8 steps (the D's) for product and process improvement. The 8 steps are: 1) use a team approach, 2) describe the problem, 3) implement short-term corrective actions, 4) define and verify root causes, 5) verify corrective actions, 6) implement permanent corrective actions, 7) prevent recurrence, and 8) congratulate the team. The 8D process emphasizes using a team to solve problems and implements both short-term and permanent corrective actions to eliminate the root cause and prevent future recurrence.
This document discusses quality and quality tools for problem solving. It begins with definitions of quality, including that quality means meeting customer needs and including the customer perspective. It then discusses total quality management and elements of customer satisfaction. It introduces several quality tools for problem solving, including the seven basic QC tools, five whys, and Shainin techniques. It provides examples of using these tools, such as a fishbone diagram, checksheet, and component search. The overall document provides an overview of quality concepts and tools that can be used to solve problems and improve processes.
The document discusses Lean Six Sigma and how it applies in healthcare. It provides an overview of Lean Six Sigma, including definitions of Lean and Six Sigma. It then gives examples of Lean Six Sigma projects at St. Elizabeth Regional Health, such as reducing door-to-balloon time for heart attack patients and improving operating room turnover times. The presentation aims to show how Lean Six Sigma principles can help healthcare organizations improve quality, safety, efficiency and patient satisfaction.
The document provides an overview of Six Sigma, including:
1) It defines Six Sigma as a methodology for continuous improvement and creating high quality products and processes using statistical tools.
2) It discusses the origins and growth of Six Sigma at Motorola and GE in the 1980s-1990s.
3) It describes the DMAIC methodology used for process improvement projects and the roles of Master Black Belts, Black Belts, and Green Belts in a Six Sigma organization.
Chapter 7 Management Concultancy by CabreraKriza Matro
The document discusses the stages of a management consulting engagement including negotiating the engagement, engagement planning, conducting the assignment, and evaluating the engagement. It describes the basic contents and purposes of an engagement plan, proposal letter, and work plan. It also discusses problem identification, data gathering techniques, data analysis approaches, solution development, implementation, and follow-up evaluation.
Lean Six Sigma Course Training Part 16Lean Insight
Here is the Lean Six Sigma Course Training Part 16, presented by Lean-insight.om
Are you looking for six sigma related courses in Bangalore, then consult lean-insight.com
Courses:
Six Sigma Training
Six Sigma Green Belt Training
Six Sigma Black Belt Training
Lean Six Sigma Training
For more details visit: http://lean-insight.com/six-sigma-training-bangalore/
- The document discusses the origins and development of Lean manufacturing and Six Sigma processes at Toyota Motor Company in the 1950s as they struggled with limited resources. Engineers Taiichi Ohno and Shigeo Shingo developed the Toyota Production System (TPS) to reduce waste and increase efficiency.
- TPS and Six Sigma methodology focus on reducing defects and process variation to improve quality and efficiency. When implemented together as Lean Six Sigma, they provide a systematic approach to continuous process improvement.
- Lean Six Sigma can be applied to manufacturing and service industries to reduce waste and improve processes in order to increase customer satisfaction and cost savings. The document outlines a sample deployment plan to implement Lean Six Sigma at an organization.
The document outlines an agenda for a workshop on change management methodologies and approaches for successful IT-healthcare projects. The workshop will cover understanding change management, Prosci and CAP change management methodologies, the relationship between change management and project management, and real-life use cases from MOH hospitals. It will define change management and discuss states of change, reasons for managing change, and choices individuals can make at different stages of a change process to have positive or negative outcomes. The goal is to provide guidance on successful change management.
This document discusses the application of Lean Six Sigma (LSS) processes to improve drug discovery within AstraZeneca. It describes a LSS project conducted within the Discovery Drug Metabolism and Pharmacokinetics department. The project aimed to improve the process of gathering pharmacokinetic data for lead optimization projects within tighter timelines. Through defining, measuring, analyzing, improving and controlling the process, the project identified inefficiencies and variability that could be addressed. Implementation of changes resulted in dramatic reductions in variability and turnaround times for providing pharmacokinetic data to meet project needs.
8D Training Material From VDiversify.com | 8D Training Material PDF Free Down...VDiversify
Note: Whoever is using this Training Material on their Website shall Link back to www.vdiversify.com as the Original Author...
The 8D (Eight Disciplines) approach is a robust and systematic problem-solving process or methodology, that is widely adopted in the manufacturing, process and other industries.
This 8D training material is completely free and can be used by any organization, professionals, engineers, trainers or teachers all over the world for teaching its employees or students.
The document discusses effective corrective action programs. It defines a corrective action program as a process that manages various inputs like non-conformances, audits, and complaints. It also manages resources to provide training on techniques like team problem solving. The ideal program applies a problem solving method like 8D across the organization and continuously improves by learning from results and implementing preventative actions.
1. Change management is crucial to the success of any CRM project as it focuses on addressing the behaviors, attitudes, and culture within an organization.
2. An effective change management plan involves formalizing the process, defining the program, establishing management structure, communicating to stakeholders, and involving people to create champions of change.
3. Key components of change management include understanding the business, people, process, and technology dimensions of change and having a plan to address each area.
ABOUT THE TRAINING PROGRAM :-
Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events. The practice of RCA is predicated on the belief that problems are best solved by attempting to address, correct or eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. By directing corrective measures at root causes, it is more probable that problem recurrence will be prevented.
DESIGNED FOR :-
Managers, Engineers, Supervisor and officers engaged in maintenance operation and engineering activities.
OBJECTIVE :-
At the end of the training program, participants will be able
- To gain a basic understanding of the problem solving and decision-making process and the applicable quality tools that support this process.
- To develop specific competencies to use the structured approach to problem solving and decision making and the supporting quality tools.
TRAINING PROGRAM COVERAGE :-
- Basic knowledge about RCA program.
- What are the RCA tools ?
- More about Why- Why analysis ?
- Videos and case studies on RCA
The document provides guidance for healthcare organizations to improve the patient experience through quality improvement projects. It outlines a three-phase process: planning, executing, and reflecting. The planning phase involves creating a "blueprint for success" which identifies the priority area, leadership team, aims, deliverables, scope, sponsor, and expectations. It emphasizes establishing effective multidisciplinary teams that include patients. The executing phase provides strategies, tools, and tips for implementing ideas. The reflecting phase involves analyzing current processes and identifying opportunities for change. The document aims to guide organizations through each step to achieve successful quality improvement.
The document discusses applying lean principles to business processes and administrative functions, not just manufacturing operations. It provides an overview of common constraints that arise from support areas like sales, purchasing, engineering, and accounting. These constraints can inhibit improvements achieved on the shop floor. The author advocates using tools like strategic alignment, process mapping, and value stream analysis to identify waste and constraints in business processes. Addressing these administrative constraints through techniques like standard work and visual management can help sustain lean initiatives and further reduce bottlenecks to operations.
The document provides an overview of key business improvement methodologies including Total Quality Management (TQM), Lean, and Six Sigma. It discusses the origins and key principles of each approach. TQM emerged from the Japanese quality evolution of the 1950-1980s and focuses on customer satisfaction through continuous improvement and employee involvement. Lean focuses on eliminating waste through flow and pull systems. Six Sigma aims for near perfect process performance through definition, measurement, analysis, improvement and control using statistical tools. The document also explores the integration of Lean and Six Sigma approaches.
The document discusses the 8D problem solving approach, which is an eight step method used to resolve chronic and recurring problems. It begins by explaining the 8 disciplines and when an 8D approach would be appropriate to use. It then describes each of the 8 steps in detail: 1) Team Formation, 2) Problem Description, 3) Containment Actions, 4) Developing Root Causes, 5) Developing Permanent Corrective Actions, 6) Implementing Permanent Corrective Actions, 7) Preventing Reoccurrences, and 8) Recognizing the Team. Key aspects of each step like necessary tools, checkpoints, and responsibilities are outlined. The document provides an in-depth explanation of applying the 8D method
This document provides an introduction to systematic problem solving using the 8D method. It discusses the purpose and content of the training, which is to teach participants a disciplined problem solving approach. The training schedule is outlined, which includes exercises to apply the 5 pillars of 5S: Sort, Set in Order, Shine, Standardize, and Sustain. Types of problems are defined, including sporadic versus chronic problems. The 8D problem solving model is introduced, which follows a plan-do-check-act cycle. Key aspects of systematic problem solving such as defining the problem, understanding root causes, using data and tools, and preventing recurrences are also outlined.
The document discusses using the DMAIC process for SEO projects. DMAIC is a structured problem-solving methodology originally developed by Motorola for process improvement. It stands for Define, Measure, Analyze, Improve, and Control. While originally used for manufacturing, DMAIC can also be applied to digital marketing projects by defining problems, measuring key metrics, analyzing data to determine root causes, improving processes, and controlling changes. The document provides details on carrying out each step of the DMAIC process for SEO projects.
This document provides an introduction to the Plan-Do-Study-Act (PDSA) cycle for quality improvement. It explains that PDSA cycles allow for testing changes on a small scale through iterative learning. Changes are implemented in controlled steps to identify problems early before full implementation. The document prompts the reader to think of an accreditation standard they want to improve and develop a PDSA cycle to test changes toward meeting that standard. It emphasizes that PDSA cycles incorporate documentation and data over time to support local learning and sharing of lessons with others.
This document discusses the 8D problem solving methodology used in the automotive industry. 8D stands for 8 disciplines or 8 steps and was introduced by Ford Motor Company in the late 1980s as a systemic problem solving approach. The 8 steps include establishing a team, defining the problem, implementing containment, identifying the root cause, choosing and verifying permanent corrective actions, implementing the actions, and preventing recurrence. Visualization techniques and a focus on facts are emphasized to support analyzing problems and identifying root causes. The goal of 8D is to stop issues from recurring through a disciplined process.
The document discusses the 8D problem solving process which consists of 8 steps (the D's) for product and process improvement. The 8 steps are: 1) use a team approach, 2) describe the problem, 3) implement short-term corrective actions, 4) define and verify root causes, 5) verify corrective actions, 6) implement permanent corrective actions, 7) prevent recurrence, and 8) congratulate the team. The 8D process emphasizes using a team to solve problems and implements both short-term and permanent corrective actions to eliminate the root cause and prevent future recurrence.
This document discusses quality and quality tools for problem solving. It begins with definitions of quality, including that quality means meeting customer needs and including the customer perspective. It then discusses total quality management and elements of customer satisfaction. It introduces several quality tools for problem solving, including the seven basic QC tools, five whys, and Shainin techniques. It provides examples of using these tools, such as a fishbone diagram, checksheet, and component search. The overall document provides an overview of quality concepts and tools that can be used to solve problems and improve processes.
The document discusses Lean Six Sigma and how it applies in healthcare. It provides an overview of Lean Six Sigma, including definitions of Lean and Six Sigma. It then gives examples of Lean Six Sigma projects at St. Elizabeth Regional Health, such as reducing door-to-balloon time for heart attack patients and improving operating room turnover times. The presentation aims to show how Lean Six Sigma principles can help healthcare organizations improve quality, safety, efficiency and patient satisfaction.
The document provides an overview of Six Sigma, including:
1) It defines Six Sigma as a methodology for continuous improvement and creating high quality products and processes using statistical tools.
2) It discusses the origins and growth of Six Sigma at Motorola and GE in the 1980s-1990s.
3) It describes the DMAIC methodology used for process improvement projects and the roles of Master Black Belts, Black Belts, and Green Belts in a Six Sigma organization.
Chapter 7 Management Concultancy by CabreraKriza Matro
The document discusses the stages of a management consulting engagement including negotiating the engagement, engagement planning, conducting the assignment, and evaluating the engagement. It describes the basic contents and purposes of an engagement plan, proposal letter, and work plan. It also discusses problem identification, data gathering techniques, data analysis approaches, solution development, implementation, and follow-up evaluation.
Lean Six Sigma Course Training Part 16Lean Insight
Here is the Lean Six Sigma Course Training Part 16, presented by Lean-insight.om
Are you looking for six sigma related courses in Bangalore, then consult lean-insight.com
Courses:
Six Sigma Training
Six Sigma Green Belt Training
Six Sigma Black Belt Training
Lean Six Sigma Training
For more details visit: http://lean-insight.com/six-sigma-training-bangalore/
This document outlines a seven step process for Corrective and Preventive Action (CAPA) programs: 1) Identification, 2) Evaluation, 3) Investigation, 4) Analysis, 5) Action Plan, 6) Implementation, and 7) Follow-Up. It defines corrective and preventive actions and provides examples. A comprehensive CAPA process identifies problems, determines the root cause, develops a plan to fix the problem and prevent recurrence, implements the plan, and ensures effectiveness. The seven steps provide a framework to systematically address issues in a way that satisfies regulatory requirements and drives continuous improvement.
The document discusses the importance of taking a big picture view before solving a problem. It explains that seeing the overall context helps with identifying stakeholders, defining roles and responsibilities, estimating tasks, and determining deliverables and processes. Taking a big picture perspective allows analysts to understand business problems and opportunities more fully in order to determine the best solution approach. The document then discusses different types of business analysis approaches and how they relate to factors like formality, change management, communication, and complexity.
These slides contain general advice for considering an ALM tooling solution. This includes management of requirements, tests and defects. It is a draft release.
Principles of effective software quality managementNeeraj Tripathi
The document discusses principles of effective software quality management. It lays out the CERT framework which includes 4 themes: customer experience, enabling environment, repeatable and reusable processes, and time to market. The framework is designed to guide organizations to the most effective quality processes and improve customer satisfaction. Key aspects discussed include actively involving customers, establishing a shared vision, encouraging innovation, and focusing on metrics to measure progress.
This document provides a summary of a training presentation on CAPA (corrective and preventive action). The training covers 5 learning segments: 1) CAPA general information, 2) identification of the problem, 3) evaluation, investigation and analysis of the problem, 4) development of an action plan, and 5) implementation and follow-up of the action plan. Segment 1 defines CAPA and the difference between corrective and preventive actions. It also discusses the objectives, regulations and importance of the CAPA process. Segment 2 covers reporting the source and details of a problem and determining supporting evidence. The training is intended to provide an overview of the full CAPA process.
The document provides a 10-step process for evaluating and selecting software and service providers. Key steps include creating a project team, identifying information needs, prioritizing business requirements, pre-qualifying potential solutions, validating references, making a decision, establishing an implementation plan, and negotiating agreements. The summary advises investing resources in preparation to ensure getting the best service and product.
Title of PaperYour nameHCA375– Continuous Quality Monito.docxjuliennehar
Title of Paper
Your name
HCA375– Continuous Quality Monitoring and Accreditation
Type Instructor Name Here
Type Date
HCA375 - WEEK 4 ASSIGNMENT
PART 1 – DETAIL OF THE ADVERSE EVENT CHOSEN
Refer to the instructions in the Week 4 Assignment of your online course to understand what is expected in each row. This completed template should be between eight to ten pages in length. Include APA citations within the description row where appropriate. List your references in APA format according to the Ashford Writing Center guidelines on the last page of this template.
CONTENT
DESCRIPTION
ADVERSE EVENT
HISTORICAL BACKGROUND
LEGAL & ACCREDITING AGENCY REQUIREMENTS
CQI TEAM COMMUNICATION
OPERATIONAL OR SAFETY PROCESSES
IMPACT OF THIS EVENT
WEEK 4 ASSIGNMENT
PART 2 - GRAPH THE DATA
You are tasked with graphing the data in Excel for your chosen event. The data is located in the classroom under the Week 4 Assignment Directions. Make sure to use only the data for your chosen event. The directions identify which columns of information to use depending on the chosen adverse event. Once you complete the graph in Excel, copy/paste your graph below.
Include an analysis of the data in paragraph format.
Discuss the frequency of the adverse event as compared to the increase or decrease of patient discharges.
What is the data telling you?
What possible factors in your opinion could be attributed to the change?
WEEK 4 ASSIGNMENT
PART 3 – CQI TOOL
· Choose one of the CQI Tools listed below to illustrate the use of the tool with your chosen Adverse Event.
· You will be responsible for creating the CQI Tool, completing the tool, taking a screenshot, and copying/pasting the screenshot into the space below. If you are unfamiliar with these tools, please refer to the recommended readings, specifically the article from Week 2, which is listed below. You can locate the article in the Ashford Library.
· In addition, as a learning resource, the CQI tools listed below are hyperlinked to the Institute for Health Care Improvement website, which discusses and illustrates examples of each type of tool.
Siriwardena, A. (2009). Using quality improvement methods for evaluating health care. Quality in Primary Care, 17(3), 155-159. ISSN: 1479-1072 PMID: 19622265
· Choose a CQI Tool that best suits your chosen Adverse Event from the following list.
· Fishbone (Cause and Effect) Diagram
· Flowchart
· Pareto Diagram
WEEK 4 ASSIGNMENT
PART 4 - FUTURE PREVENTION
APPLYING PDSA - Worksheet
PHASE
PHASE ACTIVITIES
EXPLANATION
PLAN
Problem
Objective
Team members
Communication
Data collected
Pilot phase
DO
Three possible solutions
One solution to implement
Result of pilot (create own scenario)
Methods of communication
STUDY
Summarize data
Observations and problems
Comparison of pilot plan to pilot results
Revisions needed to meet objective
ACT
Revised improvement plan
How to Implement the plan hospital wide
Plan for monitoring the improvemen ...
This document discusses benchmarking as a tool for continuous improvement in risk management. It defines benchmarking as a formal and ongoing process of comparing business practices to those recognized as best-in-class for the purpose of meeting or surpassing industry standards. The document outlines key steps in an effective benchmarking process, including planning, analysis, integration, action, and maturity. It provides examples of quantitative and qualitative areas that can be benchmarked in risk management and emphasizes the importance of analyzing processes, not just outcomes.
Process Maturity Model by 3P AssociatesBrian Pettit
The document provides an overview of the Process Maturity Model (PMM) which is used to guide continuous process improvement. The PMM has five levels which help organizations see "what's next" in their improvement journey. Continual improvement is important for competitiveness, customer satisfaction, and business growth which leads to more jobs.
This document provides an overview of Six Sigma, including:
1. It discusses the historical origins of Six Sigma in Motorola in the 1980s and how it has since been widely implemented.
2. It describes Six Sigma as focusing on reducing process variation and preventing deficiencies, and defines it as a system for achieving business success through data-driven analysis and process improvement.
3. It outlines the five phases (DMAIC) of a Six Sigma project: Define, Measure, Analyze, Improve, and Control which are used to identify and solve chronic quality problems.
1Grand Canyon UniversityInstructor Name MIS-652 BusinesEttaBenton28
1
Grand Canyon University
Instructor Name:
MIS-652 Business Process Analysis
December 1, 2021
Introduction
Cummins is a global engine manufacturer that also designs and manufactures turbochargers for engine applications. Cummins Turbocharger is the market leader in medium and heavy-duty car applications worldwide.
The Process and Relevant Data Comment by Seon A Levius: Since you are using “Cummins” in this section, you need to pinpoint some process problem with data issues for optimization. The optimization or improvement can be for both the process and technology.
Prototype - A Model of the Construction Process: The organization's prototyping process is ineffective and results in a lengthier lead time in comparison to client needs. According to data from the last six months, the average lead time for proto-sample building is approaching 12 days, rather than the five days requested by the customer.
Process Improvement Methods Comment by Seon A Levius: In this section you will basically explain how you will improve the process problem you identified above. This is basically the articulation of your solution (which must for this case include technology optimization). Also, how will you evaluate it.
You mentioned Six Sigma as the tool to enhance the process. But that is not what we want here. Six Sigma can be the tool you used to evaluate the proposed solution to the problem you identified.
So, in this sense, I didn’t see any articulation about how you will evaluate your improvements to ensure, they are efficient and effective.
For example, Six Sigma can be used as the process improvement method. The Define, Measure, Analyze, Improve, and Control (DMAIC) sub-methodology within Six Sigma can be helpful in defining the details of the future state process and Key Performance Indicators (KPIs) that the future state process should be able to meet.
Other methods in our reading this week that can be explored includes PDCA (Plan Do Check Act).
Six Sigma is a technique for process improvement. Six sigma methodology is being designed for process improvement and the implementation of six sigma tools in order to correctly assess the process and achieve improvement (Thomas, et al., 2017)
The following format explains the problem statement and execution of the process improvement method.
Problem Statement
Articulate your problem statement here
Problem Statement Worksheet
Original problem or focus question
The lead time for the proto sample process is longer than anticipated by the customer.
12 days rather than 5.
Stakeholders who are most affected by the problem
The Customer prototyping team and the Company program management team are the most impacted by this issue.
Type of Problem
Problems with resources and processes Comment by Seon A Levius: Technology has to be one of the problems
Suspected cause of the problem
Suspected reasons based on the cross functional team's root cause analysis are as follows.
1.Because the process is dependent ...
In today’s global marketplace, successful companies must be able to integrate and quickly view quality audit information from their manufacturing sites all over the world. This strategic capability has become even more important as manufacturers have moved offshore and have become more complex. The value and immediacy of quality assurance data is a critical element to the survival of competitive manufacturing organizations. Software systems can address these issues.
Source:
Lyons Information Systems, Inc
http://www.lyonsinfo.com
The RCCA PPT is an excellent training tool to implement into your functional group or business.
It basically forces you to peel the onion on a failure as far back until you’ve reached the root cause whereas in some cases it could be several.
It incorporates the 5 whys and the problem solving technique.
Running head: IMPROVEMENT OPPORTUNITY 1
IMPROVEMENT OPPORTUNITY 3
Quality Tool Analysis
The supply chain management sphere has an issue when considering a pharmacy facility organization. The problem with the pharmaceutical supply chain operations has resulted from all individuals lacking access to the most noteworthy quality medication and in addition keep up levels in medical care that occurs in the arrangement of supplying medicine, notwithstanding giving the improvement of new knowledge, aptitudes and systems that invigorate the advancement of medicine supply chain management. The quality tool used to recognize these issues is data collection sheet which gathers the essential information to have the capacity to answer any inquiries that may emerge. The quintessence of the data is that the reason for existing is apparent and that the data mirrors the fact of the matter, is anything but difficult to gather and utilize. A quantitative method was used to gather the data. The data collection sheet is being used in the dispersion of factors of the articles delivered, classification of broken things locating of the defects of the pieces, recognizing reasons for deformities and verification check or support undertakings (Awad, 2012).
To arrive at the problem, a questionnaire was utilized together with the data collection sheet. There was a clear framework on how data was to be gathered and with what sort of document will be made and how the gather data ought to be utilized. How the data will be analyzed was additionally sketched out, and the individual who ought to oversee gathering the data was distinguished. For the optimization of data accumulation, Sharp and McDermott (2009) suggest that the data collection be finished by an experienced auditor and in an arbitrary example of the exercises, of the general population and of the groups of the territories that they ought to be observed. The association recognized an experienced auditor was utilized to gather data and examine it since they have a high likelihood of giving precise data.
Stakeholder Analysis
Commonly, as an expert, one needs to think the what before the who when confronting an undertaking. Along these lines, they underscore the deliverables instead of the general population. The principal procedure of the communication knowledge zone, to be executed in the initiation of the task, is to identify the individuals with an interest.
One method for this procedure is partner examination, which a procedure of systematically collecting and investigating quantitative and qualitative data with the end goal to figure out what premiums specific must be considered all through the venture. It permits to recognize the interests, expectations, and impact of the interested individuals and relates them to the motivation behind the underta.
This document discusses continuous process improvement and problem solving methods. It begins by defining key terms like process, input, output, and the input-output process model. It then discusses Juran's trilogy of quality planning, quality control, and quality improvement. Various improvement strategies are discussed like repair, refinement, renovation, and reinvention. The document also covers different types of problems like compliance, unstructured, efficiency, process design, and product design. It explains the PDSA (Plan-Do-Study-Act) cycle and how it is used for continuous improvement. Finally, the seven phases of the problem solving method are outlined, beginning with identifying opportunities for improvement.
The Disaster Recovery Plan Sumanth Lagadapati[email protecte.docxtodd241
The Disaster Recovery Plan
Sumanth Lagadapati
[email protected]
Introduction
Many companies don’t have a disaster recovery plan often there is a desire for a DRP.
The level of effort and\or cost required to create DRP can cause this project to have a low priority relative to other more immediate projects.
A DRP is viewed as "nice to have" or "just insurance that will not be used ", and not as a critical business component.
That is, until there is a failure that causes a significant outage or loss of data (often at a significant cost to the business).
It is my opinion that every company could benefit from both a disaster recovery plan and a business continuity plan (BCP)
Investing in a DRP and BCP is just as an important for most business in my opinion.
Where do you start?
The first step is to create a DR team and this includes an:
Executive sponsor.
DR coordinator.
Team leaders (there will be several groups and possibly subgroups).
Team members.
This people should be designated as either primary or backup for position, with every position having more than one person assigned this to minimize people as a single point of failure.
The goal is to have the expertise to help develop the various recovery procedures, and is committed to success of the overall effort.
Where do you start? cont…
The next step is to define business goals.
The goal should address items such as:
What functional areas need to be recovered?
What length of time is acceptable for recovery?
What amount of data loss is acceptable?
This often involves prioritization and a cost-benefit analysis to determine the worth of recovery (i.e. something that may be premature at this phase of the project).
Understand the business goals and objectives
To find out what that really entails you must know:
What are the critical systems?
What are the key processes and applications?
What are the dependencies on other systems?
This includes:
Data transfers.
Manual processes
Remote processing
Then documents these processes.
Because there is interaction with dependencies on other systems and user interface, and the sensitivity of the data.
Once the systems have been identified, attempt to quantify their impact relative to the overall business goals.
Identify specific requirements
Everyone involve with this effort (including upper management within a company) needs to have a single vision of what success look like, without this you risk wasting time and money on a plan that may be viewed as a failure.
Identify key personnel
These people may not be part of the DR team, but they are important. (For example who has the authority to declare a disaster?)
This list should be maintained both by name and by role; it should be validated and updated frequently.
Identify single point of failure
The overall goal of this step is to mitigate unnecessary risk.
The scope of this effort includes people, software, equipment, and infrastructure.
It i.
Similar to Nadcap newsletter 1607-12 for website (20)
The Disaster Recovery Plan Sumanth Lagadapati[email protecte.docx
Nadcap newsletter 1607-12 for website
1. NADCAP NEWSLETTER
JULY 2016
C O N T E N T S
1 RCCA Nadcap Style
5 Nadcap Welding Audit
Insights
11 Review of Nadcap Mark
of Conformity Usage
12 How to use the
Qualified Manufacturers
List
15 Nadcap Supplier Survey
Results
WELCOME TO THE FOURTH ISSUE
RCCA NADCAP STYLE
In the March 2016 issue of the Nadcap Newsletter, part one of Getting To
The Root was published. That article provided an overview of the initial
stages of root cause analysis and corrective action implementation
including containment, forming a team, gathering and analyzing
data and determining causes and impacts. Part two focuses
on identifying a solution and assessing it to ensure
effectiveness.
Continued on next page
This is the fourth issue of this Nadcap newsletter. PRI has been publishing and
sharing this content for one year now. I would like to thank everyone who
has given us feedback to help improve this newsletter, and for the positive
comments my staff and I have received on the content to date.
The intent of the newsletter continues to be to develop content for companies
that are not normally able to send a representative to Nadcap meetings, to
share technical information/knowledge that will help them better prepare for
a Nadcap audit and understand how to utilize Nadcap effectively to improve
their performance.
Each newsletter includes articles designed for the whole Nadcap Supplier
community. In this issue, there is an article clarifying the appropriate use of
the Nadcap mark of conformity, and one with tips about how to best use the
online Qualified Manufacturers’ List (QML) on eAuditNet. Also highlighted are
the results of the biennial Nadcap Supplier Survey that the Nadcap Supplier
Support Committee released late last year, as well as the continuance of the
article on root cause corrective action from the previous newsletter edition.
In addition to general Nadcap articles, each newsletter will have a particular
technical focus. In this issue, there is detailed information regarding Nadcap
welding audits. Nearly 500 Nadcap welding audits are conducted annually,
yet we know that many people are not able to attend
Nadcap meetings and benefit from free training and
other information shared there.
I hope you continue to find the content valuable.
Joseph G. Pinto
Executive Vice President & Chief Operating Officer
Performance Review Institute
I N B R I E F. . .
Nadcap is an approach to
conformity assessment that
brings together technical
experts from Industry to
manage the program by
establishing requirements
for accreditation, accrediting
Suppliers and defining
operational program
requirements. This results
in a standardized approach
to quality assurance and
a reduction in redundant
auditing throughout the
aerospace industry.
Nadcap is administered by
the Performance Review
Institute (PRI), a not-
for-profit organization
headquartered in the USA
with satellite offices in
Europe and Asia.
www.p-r-i.org/Nadcap/
Overview of Root Cause Cause Corrective Action (RCCA) - Nadcap
Style (Part Two)
2. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
2
RCCA NADCAP STYLE
Continued from previous page
Determine Corrective Actions
Having built a robust cause chain, you should be in a
position to confidently identify the problems in need
of resolution. While some may have been addressed
as part of your immediate containment activity, others
will require a more in depth solution i.e. root cause
preventive action.
Preventive corrective action can also be thought of as
sustaining, because you cannot prevent the event at
this point. It has already occurred. Actions taken now
are intended to prevent the problem from recurring.
The goal is to break the cause chain by addressing
the contributing causes as well as the root cause. It is
important to resolve the contributing causes, not just
the root cause, because failure to do so could lead to a
contributing cause becoming a future root cause.
Although preventive action may be one action, it could
also be a series of actions, that positively change or
modify system performance. Nadcap is, after all, a
process audit so this is about making constructive
changes to the systems that support the process in order
to prevent event recurrence. Preventive action focuses
on systemic changes and the points in the process where
there is potential for failure. This includes contributing
causes as well as direct and root causes.
The focus of preventive action is not individual
performance, human error or personnel shortcomings.
Consequently, “Operator error” is not an acceptable
root cause response to a non-conformance identified
in a Nadcap audit. It is the company and its processes
being audited, not the individual.
So the question to ask yourself, if you get stuck at the
point of human error as a root cause, is: if that individual
was not working here anymore, would that make it
impossible for this issue to occur again?
The answer is almost certainly no. If one individual can
make a mistake, it means there is elasticity in the system
to allow them to do so, and it is the responsibility of
the company to close those gaps, whether they are
procedural, training or otherwise. When developing the
solution, it is worth bearing some guidelines in mind:
1. Accept that there is no perfect solution. Any solution
that you and your team think of will be subject to a
number of factors (see a - f below). In some cases,
therefore, you may be required to make a judgment
call as to the appropriate solution, based on your
knowledge of the company and the issue.
The list below is not exhaustive, but provides some
of the key considerations:
a) Feasibility
The solution needs to be achievable given the
resources and timeframe available to the company.
Commercial restrictions play a part in any business
decision, and this is no different.
b) Effectiveness
There must be a reasonable expectation that
the solution will fix the problem that has been
identified. A solution that is not effective is
not only a waste of time and resources, but it
creates a risk that the problem will recur which,
apart from anything else, could result in a major
nonconformance at the next Nadcap audit due to
non-sustaining corrective action.
c) Budget
The budget should be realistic given the available
resources of the company and proportionate to the
size of the problem. There is no sense in investing in
3. 3
Event
Form Team
Identify Problem
Gather & Verify
Data
Determine Causes
& Impacts
Direct Root Contributing
Determine
Corrective Actions
Specific Sustaining
Mistake Proofing
Source Self Successive
Implement &
Follow Up
Solution
Acceptable?
Report
ProblemDefinitionAnalysisSolutionAssessment
Containment
Action
No Yes
Document
Team
Document
Causes
Document
Corrective
Actions
Document
Follow-Up
a solution that is out of all proportion to
the original problem.
d) Employee Involvement
The staff impacted by the event should
be involved in finding the solution. Their
participation will help encourage their
support for the solution and as they
are best positioned to understand the
issue, their insight will be invaluable in
identifying an effective solution.
e) Systems
As previously described, the focus of
the corrective action should be on the
systemic issue in the process, not on
the personnel involved. While operators
do make mistakes, the key is to identify
the conditions that made that mistake
possible. For example, were the
instructions clear and easily accessible?
Had there been recent personnel
changes? etc.
f) Contingency Planning
While it is expected that the solution will
succeed at addressing the issue, it may be
flawed. Critical parts of the solution itself
should be subject to contingency planning
to ensure that a misstep at any point
does not cause a breakdown of the entire
solution.
2. Take time to reach a solution and
ensure you give adequate
Continued on next
page
4. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
4
consideration to alternatives. It is key to have an
open mind and to follow the chain where it leads,
even if that is to your department or a procedure
you have written. Always remember that the key is
to fix the problem.
3. Be open to the possibility that what you have
identified as the root cause may actually be a
symptom of a larger problem. Keep following the
chain as far as is reasonable and create as many
chains as needed to exhaust the possibilities within
the company’s control.
4. Challenge assumptions. You may know your
operation well, but be prepared to revisit
assumptions that are not supported by evidence.
Make sure you have the evidence available because
although you may not need it, the Nadcap auditor,
auditor reviewer and Task Group might.
5. Evaluate the corrective action to determine whether
it lowers the risk to an acceptable level, and also
whether implementing it might have any adverse
effects that outweigh the benefit. This requires
careful consideration so that the solution does not
result in additional problems.
Assessment
As part of the assessment of the corrective action(s), it is
important that a member of the team conducts a follow-
up review to ensure that they were fully and properly
implemented as stated in your non-conformance
response in eAuditNet, as this is what the next auditor
will be looking to verify.
The corrective actions must be instituted as stated
and it is key that someone is given the responsibility
of ensuring that is the case. Part of their task is to read
the corrective action response literally and check that
it was achieved according to what was stated, including
the timeframe, documentation modifications, training,
calibration and so on.
When developing the corrective actions, bear in mind
the level of scrutiny that they will be subjected to, and
ensure that the team can deliver according to what is
written. Be careful in the terminology you use - words
like “everyone”, “always” etc. may cause you problems
later. Remember that you will have to show that you
have done what you said you would through objective
evidence. The easiest way to be able to do that is to
have that at the front of your mind during the process of
developing and writing the corrective actions.
Another part of the assessment process is to validate
the effectiveness of the corrective actions. Did they
achieve the intended outcome? The only way you will
know is by defining the criteria for effectiveness and
acceptability in advance. Without these benchmarks, it
will be difficult to measure the outcome.
The first step, then, is to define the criteria and the
frequency required for evaluation; secondly, to conduct
the evaluations against the stated objectives at the
stated frequency and record the results; and finally, to
review the results and close, or revisit, the cause chain
as appropriate.
Again, bear in mind that the effectiveness of the
corrective actions will be verified by the Nadcap auditor
during subsequent audits. Non-sustaining corrective
actions are one of the biggest sources of findings across
all Task Groups and can be cause for removal of Supplier
Merit so it is well worth putting in the time up front.
Part one of RCCA Nadcap Style was published in issue
three of the Nadcap Newsletter, dated March 2016, and
is available on the PRI website www.p-r-i.org under Key
Documents.
RCCA NADCAP STYLE
Continued from previous page
5. 5
NADCAP WELDING AUDIT INSIGHTS
The Nadcap Welding Task Group was established in
1994 and is currently led by Chairperson Steve Tooley
from Rolls-Royce, supported by Vice Chairperson Holger
Krueger from Airbus. Within the Task Group, there are
over 50 industry representatives. They participate in
technical discussions and decision-making three times
per year at Nadcap meetings.
Additionally, Nadcap welding information is shared at
regional technical symposia organized by PRI, the not-
for-profit organization that administers Nadcap. For
more information on the upcoming regional technical
symposia, please contact PRI at pri@p-r-i.org
For those industry stakeholders who are unable to
attend the Nadcap meetings or the technical symposia
and benefit from the opportunity to participate and
learn about Nadcap welding audits face-to-face, the
intent of this article is to provide some insight into
common nonconformances (NCRs) found during Nadcap
welding audits, from a “lessons learned” perspective.
Process specific requirements have been developed
by the Welding Task Group and are contained in the
AC7110 series of checklists:
• AC110: Welding/Torch and Induction Brazing
• AC110/1: Brazing (Torch and Induction)
• AC110/2: Flash welding
• AC110/3: Electron Beam Welding
• AC110/4: Resistance Welding (Spot, Seam,
Projection)
• AC110/5: Fusion Welding
• AC110/6: Laser Welding
• AC110/7: Rotational Friction/Inertia Welding
• AC110/8: Diffusion Welding
• AC110/9: Percussion Stud Welding
• AC110/12: Welder/Welding Operator Qualification
• AC110/13: Evaluation of Welds
These checklists are available on eAuditNet under
Resources - Documents - Audit Checklists and, as with
any Nadcap audit, you should download and review
them in detail in advance of the actual Nadcap audit as
part of your pre-audit preparation.
Additional information on the checklist requirements,
question intent, acceptable objective evidence,
examples of NCRs and helpful hints are included in the
audit handbooks that are also available in eAuditNet in
the Public Documents area.
Top Nonconformances in Welding Audits
In common with many other Nadcap Task Groups, the
Welding Task Group analyzes and publishes common
nonconformances identified during Nadcap audits on a
regular basis. The intent is to help suppliers avoid some
common pitfalls and strengthen their internal process
control.
To that end, as well as the common nonconformances,
the Task Groups often also provided guidance and
further information about each nonconformance.
Articles in this newsletter are written with the same goal
in mind.
The Welding Task Group most recently published an
updated document in February 2016. The most
recent guidance released by the Nadcap
Welding Task Group is below.
Continued on next page
6. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
6
The document is also posted in eAuditNet under
Resources - Documents - Public Documents - Welding -
Supplier Information. Similar documents for other Task
Groups are posted in Public Documents. It is strongly
recommended that you review the relevant files to gain
insights that will assist in Nadcap audit preparation and
success.
Nadcap Welding Audit Insights
The following checklist questions are the most common
that NCRs are written against. Additional information on
the checklist requirement including acceptable objective
evidence is included in the audit handbooks that are
available in eAuditNet under Public Documents.
1) Is there a documented procedure that controls
electrodes?
This is a new checklist requirement in AC7110/5 Rev H
paragraph 5.3.
Explanation: While control of consumable fillers has
been in place in the checklists for numerous years, the
control of electrodes has not. Auditors were witnessing
issues where electrodes were not under control, for
example not purchasing to a specification, not ensuring
the electrodes were receipt inspected, cutting of
electrodes leading to loss of identification.
Examples of findings:
• No Procedure in place that defines how electrodes
are to be purchased, inspected and identification
maintained.
• Procedure has been written but electrodes are not
being controlled per the procedure requirements.
• Electrodes are required to meet a defined
specification, but this not specified on the purchase
order.
• The incoming certification of the electrodes does
not certify the electrodes to the requirements
defined on the Purchase Order.
Helpful Hints:
• This is a new checklist requirement that many
Suppliers have not incorporated into their system.
Suppliers must review new checklist revisions and
implement changes into their system.
• Understand the requirement. Don’t assume you
already have the item under control. Many Suppliers
incorrectly assume that this applies to consumables,
when in fact it applies to non-consumable
electrodes as well.
• Review Purchase orders, receipt documentation
and electrode traceability to ensure it meets your
procedure and any specifications that are flowed by
contract.
2) Are pre-weld preparations performed as described
in documented procedures and in accordance with
customer requirements?
This is a compliance question and is in paragraphs 11, 12
and 13 of the weld process checklists.
Explanation: Written instructions may be required
by the customer(s), including joint preparation and
cleaning. The weld source must adequately define the
NADCAP WELDING AUDIT INSIGHTS
Continued from previous page
7. 7
steps and sequence of steps to be taken by the welder
in preparing and cleaning the joint, and maintaining
cleanliness after cleaning prior to welding.
Examples of findings:
• Instructions did not define the joint preparation (e.g.
hand benching + solvent wipe or hand grinding of a
V groove bevel).
• Welder was doing the ‘proper’ preparation, but the
instructions were not defined.
• Welder was not working to defined preparation
requirements.
• Cleaning not addressed either procedurally or within
the job documentation.
• Parts were cleaned and then subsequently handled
that allowed re-contamination to occur (e.g. dirty
hands, contaminated boxes).
• Instruction defined to use a particular solvent and a
different one was used.
Helpful Hints:
• In a controlled document, specify requirements
for material preparation as applicable to welding,
including cleaning, hand benching, hand grinding,
handling between cleaning and welding etc.
• Ensure cleaning is addressed procedurally and
includes customer-specific requirements, if
applicable.
• As part of audit preparation, a spot check of a few
weld schedules/procedures is recommended.
3) Has the supplier demonstrated compliance to the
welding schedule?
This is a compliance question and is in paragraphs 11, 12
and 13 of the weld process checklists.
Explanation: The supplier must demonstrate that the
parameters/setting and weld tasks specified in the
procedure are being done in accordance with the
approved document. This question is only addressing
compliance to the weld schedule in use, not compliance
to the certification, approval or documentation
requirements.
Examples of findings:
• Supplier has an approved/certified weld schedule
and it is in use at the workstation, but the welder is
using parameters outside the allowable range.
• Weld operation is being performed differently than
specified in the weld schedule (e.g. sequence of
welding).
Helpful Hints:
• Ensure that welders/welding operators are working
to the actual weld schedule/written instructions
for any production job. Pay particular attention for
compliance to weld current (for automatic welding),
gas flows and travel speed.
• Ensure welders have not changed parameters
to improve the weld without gaining the correct
authorization.
• Ensure new schedules are reviewed correctly to
avoid ‘cut and paste’ errors.
• Where parameter ranges are allowed via the
qualification, use them – do not make the schedule
too rigid.
• As part of audit preparation, a spot check of a few
weld schedules/procedures is recommended.
4) Is equipment calibrated in accordance with
established procedures?
This is a compliance question and is in paragraphs 11, 12
and 13 of the weld process checklists.
Explanation: Welding equipment requires periodic
calibration to ensure repeatability of parameters.
All equipment must be considered and addressed
procedurally. It is recognized that some equipment
may not require calibration, however this
equipment should be identified that this
is the case (e.g. a voltmeter used in
Continued on next page
8. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
8
NADCAP WELDING AUDIT INSIGHTS
Continued from previous page
manual welding may not require calibration, but it must
be noted that the meter does not require calibration).
Example of findings:
• Flow meters that do not require calibration are not
identified that calibration is not required.
• Turntables where speed is required are not included
in calibration, or verified prior to use.
• Meters not calibrated in range of use.
• Procedures do not define the equipment that
requires calibration.
• Equipment used that is out of calibration.
• New equipment not assessed and included in
calibration re-call system.
• Equipment not included in calibration re-call system.
• No traceability between equipment and calibration
report.
Helpful Hints:
• As part of audit preparation, spot check equipment
calibration (e.g. is it calibrated and is it in date).
• Define how calibration is verified procedurally.
• Welding speed may be verified prior to use by using
distance and time method.
• Verify Customer requirements and ensure these as
well as Nadcap checklist items are met.
5) Is there a documented procedure to ensure cleaning
tools, such as brushes, flap wheels, abrading tools etc.
are marked with the material
type they are used on in order to avoid cross
contamination?
This is a new checklist requirement in AC7110/5 Rev H
paragraph 7.1.3.
Explanation: In order to prevent cross contamination,
cleaning tools are restricted to the material types they
were first used on.
Example of findings:
• No documented procedure to define how the
Supplier will control cleaning tools to prevent cross
contamination.
• System is not robust enough to prevent cleaning
tools being used on more than one material type.
• Unidentified cleaning tools found in use and hence
unable to prove which material types they can be
used on.
• Cleaning tools made from materials that are
prohibited by flowed specification. E.g. carbon steel
brushes used on nickel.
Helpful Hints:
• This is a new checklist requirement that many
Suppliers have not incorporated into their system.
Suppliers must review new checklist revisions and
implement changes into their system.
• Spot check weld areas. Ensure cleaning tools are
marked with the materials they can be used on.
• There is guidance on material types in the
handbook.
6) Do qualification documents include objective
evidence that the welder(s) has satisfied the specified
vision examination requirements?
This is a question in the weld / weld operator
qualification checklist, AC7110/12 paragraph 3.3.
Explanation: To ensure that the correct vision standard
has been utilized, that vision test certification has not
expired and that records correctly document this.
Example of findings:
• Eyesight restrictions are not defined on qualification
records (required by AWS D17.1).
• Eyesight tested to the wrong requirements.
• Eyesight tests missing some element(s) of the
imposed specifications. E.g. far vision, color.
• Eyesight certification has expired.
• The qualification record is missing a restrictions box.
Helpful Hints:
9. 9
• Review all eyesight requirements that are imposed.
Ensure all imposed requirements are met.
• Where alternative tests are used, ensure that the
specification allows alternatives, and if required
that the person who has made the determination of
equivalency is qualified to make this decision.
• As part of audit preparation, perform a spot
check of eyesight records. Look for compliance to
specification requirements, that the records are
current, that restrictions are documented.
• Check welders /welding operators are using the
required vision aids.
7) Is there documented evidence that all NDT and visual
inspections (eg Visual, FPI, X-ray) have been performed
to customer requirements?
This is a compliance question and is in paragraphs 11, 12
and 13 of the weld process checklists.
Explanation: To verify that all of the weld inspections
have been performed to the correct method and
acceptance criteria.
Example of findings:
• Inspection requirements not defined in Supplier’s
documentation.
• Wrong inspection criteria defined in Supplier’s
documentation.
• Inspection performed but no criteria (e.g. weld
size flowed down). No evidence of any agreement
between Customer and Supplier when job accepted.
• No record of inspection being performed.
• No record of inspection meeting the flowed
requirements.
Helpful Hints:
• For each part ensure that the required inspection
criteria are defined and results are recorded.
• As part of audit preparation, perform a spot check
of part records. Look for compliance to specification
requirements and that the records are complete.
8) Does the welding schedule address all customer
requirements?
This is a compliance question and is in paragraphs 11, 12
and 13 of the weld process checklists.
Explanation: A weld schedule must contain all
parameters/settings required by the customer(s). The
extent of parameter documentation required may vary
by customer. Having the appropriate approvals is also
required.
Examples of findings:
• Weld schedule missing required parameters,
settings.
• Weld schedule had inadequate written instructions.
Helpful Hints:
• In a controlled document, specify all parameters/
settings required by customer(s). It’s usually best
to have one weld schedule format that satisfies all
requirements.
• Review weld schedule content as part of pre-audit
preparation.
• If the Qualification allows a range to be used then
add the range on the WPS.
9) Is there a documented procedure that defines the
specification and certification requirements including
receiving inspection verification responsibilities for the
gas?
This is a question in the fusion weld and braze checklists,
AC7110/5 and AC7110/1 at paragraph G.1.
Explanation: To ensure gas requirements are correctly
defined thereby ensuring Customer specifications
are met. Hence to ensure shield gas does not
contaminate the weld / braze. Also for torch
brazing to ensure that the fuel gas and
Continued on next page
10. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
10
oxygen are purchased consistently.
Example of findings:
• Procedure does not define the gas requirements
(specification or purity).
• Procedure does not define the gas requirements
that need to be defined in the Purchase Order.
• Procedure does not recognize unique Customer
analysis / dew point requirements.
• Procedure does not define the certification
requirements.
• Procedure does not define receipt inspection
verification responsibility.
Helpful Hints:
• Review all Customer requirements for gas
and ensure procedure is written to meet all
requirements.
• Ensure procedure defines what certification is
required.
• Ensure procedure defines who is responsible for the
verification of receipt inspection and what actions
are required of this person.
10) Can the cleanliness of filler material be
demonstrated immediately prior to welding?
This is a checklist question in the filler supplement
(which is used in several checklists for the control of
filler material).
Explanation: To prevent the use of filler material which
has been contaminated during manufacturing (i.e.
residual oils) or during storage (i.e. dust, oils, corrosion),
and to maintain cleanliness of fillers after cleaning.
Example of findings:
• Not cleaning wires or at least establishing
cleanliness prior to use.
• Wires cleaned but not checked for level of
contamination.
• Wires cleaned but then re-contaminated e.g placing
them on a dirty bench.
• Cleaning a bunch of wires together resulting in some
individual wires not being cleaned.
• Failure to keep filler tip in shielded environment
resulting in tip oxidation, and failure to remove this
tip prior to subsequent welding.
Helpful Hints:
• As part of audit preparation, a spot check of how
Operators are complying with the requirements is
recommended.
• Define how cleanliness is verified procedurally.
• After wires are cleaned, ensure they are kept clean
E.g. don’t place them on a dirty bench.
• Verify Customer requirements and ensure these as
well as Nadcap checklist items are met.
If you have any questions on this article or a Nadcap
welding audit, please do not hesitate to contact
any member of the Nadcap Welding department at
welding@p-r-i.org and we will be happy to help.
Mike Gutridge
Lead Senior Staff Engineer
T: +1 740 587 9841
E: mgutridge@p-r-i.org
Gabe Kustra
Staff Engineer
T: +1 724 772 8673
E: gkustra@p-r-i.org
Ian Simpson
Associate Program Manager
T: +44 (0) 1332 869 272
E: isimpson@p-r-i.org
NADCAP WELDING AUDIT INSIGHTS
Continued from previous page
11. 11
REVIEW OF NADCAP MARK OF CONFORMITY USAGE
Obtaining Nadcap accreditation is a remarkable
achievement. Many companies, understandably, wish to
promote their status to their customers specifically, and
to the industry as a whole. One of the ways to do this is
to utilize the Nadcap Mark of Conformity in your efforts.
The Nadcap Mark of Conformity is a version of the
Nadcap logo that accredited companies are authorized to
utilize in very specific ways, and it is important that this is
done correctly.
Nadcap logo Nadcap Mark of Conformity
The difference between the logo and the Mark
of Conformity is that the latter includes the word
Accredited. Proper use of the Mark of Conformity is
described in s-frm-48, which is located on eAuditNet
(www.eAuditNet.com) under Resources - Documents
- Procedures and Forms - Nadcap Controlled Forms - s
forms. A summary of the appropriate way to use the
Mark of Conformity is described below but please refer
to s-frm-48 on eAuditNet for full details.
One of the most important points about using the Mark
of Conformity correctly is that you must ensure that the
commodity/commodities for which your company is
accredited are detailed as well. The Mark of Conformity
should not appear alone. This enables anyone who sees
the Mark of Conformity to understand your accredited
status at a glance and avoids confusion.
Nondestructive Testing
Welding
Incorrect Correct
As explained in s-frm-48, it is the company’s
responsibility to ensure that “no confusion arises about
the scope of accreditation”. Omitting the commodity/
commodities for which the company holds accreditation
is the most common mistake made by companies using
the Mark of Conformity.
When a Nadcap accreditation is issued, camera-ready
artwork and/or electronic files are also sent. Other
electronic formats are available upon request.
In terms of application of the Mark of Conformity, it
may be used in many ways. s-frm-48 refers to company
letterhead, fax cover sheets, business cards and “other
business stationery”, as well as website, flyers, mailings,
paid advertisements in magazines and trade publications,
company promotional materials and company souvenirs.
This is a very broad list and offers a lot of opportunity to
promote your Nadcap status.
PRI has received queries in the past about putting the
Mark of Conformity on company vehicles, clothing, trade
show booths and flags, among others.
As long as the Mark of Conformity is being applied in
compliance with s-frm-48, these are all acceptable uses.
Another key point to be aware of is that the Mark of
Conformity is not transferrable between facilities or
locations. This means that companies with multiple
facilities or locations must indicate which facility or
location is accredited.
Utilizing the Mark of Conformity can be invaluable in
ensuring that the hard work of you and your colleagues
is noted by your customers and the industry at large.
If you have any questions about obtaining or using the
Mark of Conformity, please do not hesitate to
contact your Commodity Service Representative
(CSR). The list of contacts is available on
eAuditNet under Contact Us.
TM
A c c r e d i t e d
TM
A c c r e d i t e d
TM
A c c r e d i t e d
12. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
12
HOW TO USE THE QUALIFIED MANUFACTURERS LIST
All companies in possession of a valid, current Nadcap
accreditation are featured on the online Qualified
Manufacturers List (QML) on eAuditNet at
www.eAuditNet.com.
The QML serves a number of functions. For companies
with Nadcap accreditation, it provides a reliable,
independent source that they can direct their customers
to in order to verify their Nadcap status, or scope of
accreditation. For those looking to source suppliers with
confidence, the QML acts as a searchable database,
updated in real time as accreditations are granted and
expire. This enables users to find Nadcap accredited
companies in a convenient location, with the proven
capability to do the work required.
Access to the QML requires a one-time registration on
the eAuditNet website, but there is no associated cost,
and nor is there a fee to be registered on, or to access,
the database.
Once you have logged into eAuditNet, the QML can be
accessed via the Resources menu.
This takes you to the database search engine which,
based on the criteria you select, will return a list
of Nadcap accredited companies that meet those
requirements. The criteria available are:
1. Supplier name - if you want to check the status of a
specific company
2. Country - if the supplier location is a factor in the
procurement process, or to see how many other
companies in your locale hold the same status as
your company
3. State (for the USA and Canada)
4. Commodity or commodities in which Nadcap
accreditation has been granted - more than one can
be selected at a time
5. Whether the accreditation is currently live (active)
or historical. If you want to look at historical
accreditations, you can select a date range to search
within.
In addition, if you want a more in depth search, use the
Refine Search option to search by scope, sub-scope,
method or specification by clicking on a “+” sign.
1
2
3
4
5
13. 13
This gives you the option to search by specific sub-scopes. This is useful if you want to look for suppliers holding
Nadcap accreditation not just for welding but, for example, for foil spot welding and so on. The Refine Search option
allows you to search for Nadcap accredited suppliers by commodity, scope, sub-scope, method or specification.
If relevant, you can also search by compliance to unique customer requirements via the supplemental audit criteria
listed under Refine Search.
Once you are satisfied with your search criteria, click Search, or to start again, click Reset.
14. NADCAP NEWSLETTERNadcap: 25 Years of Excellence
14
After clicking Search, the database will return the results to you in the format below. For demonstration purposes,
test data is used in order that it does not become dated or misrepresentative.
The search criteria you used is displayed at the top (1), with accreditations granted merit (extended accreditation
duration based on audit performance) highlighted in a dark colour (2). Accreditations without merit are not
highlighted (3). For more information, you can click on either the company name (4) or commodity link (5).
Clicking on the Excel icon (6) will download the results to your computer where they can be saved or printed. In this
case, with only two results, that may not be necessary, but depending on the search criteria, there may be hundreds
or potentially thousands of results and the ability to view them in a format that allows you to work with the data can
be invaluable.
If you click on the company name (4) or commodity link (5), you will be able to view the details of the Nadcap
accreditation(s) held by the company. Choosing the All Certs tab (7) will display the company’s Nadcap certificate
history for all commodities, including current and expired accreditations. To view the current scope of accreditation
held by the company, click Show Scopes (8).
HOW TO USE THE QUALIFIED MANUFACTURERS LIST
Continued from previous page
1
2
2 3
6
4 5
8
7
15. 15
NADCAP SUPPLIER SURVEY RESULTS
On a biennial basis, the Nadcap Supplier Support
Committee (SSC) conducts a survey of the global supplier
base. This survey has been issued every two years since
2003, and was most recently launched in 2015.
The intent of the survey is to gather information to
improve the system and further support Supplier efforts
for the benefit of all. Survey responses are used to help
to identify the strengths of the program as well as target
efforts to improve any weak points.
The survey was available in multiple languages to
encourage international participation and benefited from
the highest number of responses ever: 3,200 individual
representatives from Supplier companies gave their
input.
At the Nadcap meeting in June 2016 in London, UK, the
results of the survey were presented, but, for those who
were unable to attend, the highlights are detailed below.
With regard to Nadcap accreditation:
• 92.8% of the respondents stated that accreditation
added value for their companies
• 87.5% agreed that quality had improved at their
companies
• 80.7% believed that holding Nadcap accreditation
has improved their customers’ satisfaction with their
companies
• 74.6% thought that being Nadcap accredited had
helped them win new customers or projects
• 68.4% stated that Nadcap had helped improve their
process efficiency
• 62.5% believed that Nadcap had contributed towards
increased revenue growth
Dale Harmon of Cincinnati Thermal Spray, SSC
Chairperson, explains why this is such an important
activity: “For over ten years now, the SSC has worked
diligently to ensure that the Supplier voice is heard
within the Nadcap program, in a number of ways. The
Survey is one of the most valuable, because it enables us
to understand the experiences of a broad cross-section
of the Nadcap Supplier community, giving us insights that
we would not otherwise have access to.”
Lei Bao of NCS Testing Technology Co., Ltd. is the SSC
Asian representative and led the 2015 Supplier Survey
team. He is delighted with the response rate: “It was my
privilege to lead such an enthusiastic team and I am very
happy that this survey received the highest ever number
of responses. Thank you to everyone who took the time
to share their feedback.”
Finally, Joe Pinto, Executive Vice President and Chief
Operating Officer for the Performance Review Institute,
which administers Nadcap added: “I have long been
an advocate of the idea that Nadcap is a program as
much for the Suppliers as it is for the Subscribers. Every
time Suppliers utilize the opportunities open to them
to participate in Nadcap, we all take a step closer to
this vision. I would like to add my thanks to the 3,200
individuals who took part in the survey. Your contribution
does make a difference.”
Work is now underway to analyze the responses in more
detail and identify appropriate actions to support the
Supplier base moving forward. Arno Toelkes of Euro-
Composites SA, the European representative on the SSC
Leadership Team, is leading the effort to analyze the
2015 Supplier Survey results.
If you are interested in participating in this important
activity, please contact NadcapSSC@p-r-i.org
16. NADCAP NEWSNadcap: 25 Years of Excellence
PRI International Headquarters
161 Thorn Hill Road
Warrendale, PA 15086 USA
+ 1 724 772 1616
Email: pri@p-r-i.org
PRI - Europe
Europe Office
1 York Street
London W1U 6PA UK
+ 44 (0) 870 350 5011
Email: pri@p-r-i.org
PRI - Asia (Japan)
Contact information to be provided at a later date
Email: hli@p-r-i.org
PRI - Asia (China)
Room 307, Building No. 1
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No. 7 Jingshun Road
Chaoyang District
Beijing 100028 P.R. China
+ 86 10 6461 9807
Email: pri@p-r-i.org
If you would like additional copies of this newsletter, please contact prinadcap@p-r-i.org