Quality Management of the Fairing Production Process

Quality Management of the Fairing Production Process

Where are we going ?

Complex is that way

Simple is this way!

Dr. LiuSMA

A Focus on Training

Julian Archer, Ashley Green, Thomas Portz, Ryan Two, Anna Vitalis

Outline Introduction

Problem Statement /Objectives

Methods Participants

Apparatus/ Materials

Procedure

Solution: Training Implementation

Assessment

Next Steps for SMA

Introduction

Series of Documents that Define Requirements for QMS

standards

Used by organizations for certification or contractual purposes

Addresses effectiveness of quality management systems in

meeting customer requirements

ISO 9001

Introduction

Requirements to be Implemented to meet certification

Ensures effectiveness of the system

Provides appropriate training to those involved in organization

Vital to establishing set standards in order to meet their goals,

as well as customer and employee job satisfaction.

ISO QMS Training Subsystem

Introduction

Required skill level for an employee to carry out their job

Supplemental training is required for employees to develop the necessary skill level required for a certain job

Assessments and evaluations will be given to ensure employees demonstrate job competence

Employees are aware of the importance of their individual responsibilities and how it adds to the overall accomplishment of their expected quality objectives

Records of employee education, skill, and experience

ISO QMS Training Subsystem Requirements

• Mission Statement– Comprehensive behavioral

healthcare– Job security and valuable training

• Values– Service– Integrity– Excellence

• Personnel– Management

• Upper• Lower

– Clients

IntroductionStewart-Marchman-Act Behavioral Healthcare

Fairing Description

Purpose

Assembly occurs in three (3) stations

Completed product delivered to Sparton

Fairing Process

Physical/Spatial Model Overview

Table

Table

TableW

orkstation # 1

Workstation # 2

Workstation#3

Raw

Material

Arrival Table

Cutting Table

Fairing Work Area

Problem Statement ISO 9001 Certification/QMS for Fairing production process

QMS should address

Organizational level of SMA

Resource Management

Production Process

Measurement, Analysis, and Improvement

Training

Goal of QMS is to consistently meet customer requirements while providing training for clients

Project Objective• Allocate ISO QMS requirements to Fairing production system

• Develop QMS and Training for Fairing production system

– Ensure that process and documentation improvements are effective and feasible

– Improved quality control through effective

• Measurement

• Management

• Documentation

Method

Top-down Approach: Driven by ISO 9001 Requirements

Models developed to address Quality Management

oFunctional Model

oOperational Model

oPhysical Model

Model Based Systems Engineering Inspired Design

Methodology Flow DiagramLiterature & Initial Review

ISO 9001 Requirements SMA Presentation Engineering Report

#1

Development of Functional

Model

Functional Allocation

Verification via Progress Report

#1

#2

Requirement Analysis

Identification of Applicable

Requirements

Translation of Requirements

Requirement Traceability

#3

QMS Training Solution

Development of Training Manual

Verification via Progress Report

#2

#4

Timeline

Timeline#1: (Week 1 – Week 2) #2: (Week 2 – Week 8 ) #3: (Week 3 – Week 4) #4: (Week 4 – Week12)

Overview of System Specific Requirements

1. Quality Management of Functions

2. Management Responsibility

3. Resource Management

4. Product Realization

5. Fairing Production

6. Measurement, Analysis and Improvement

Function OverviewFunctional Flow Block Diagram

SHELL Model

S •Software

H •Hardware

E •Environment

LL

•Liveware

Systems Engineering Considerations For Function Allocation

Function AllocationFunction Allocation for the Quality Management of Functions (1.0)

Sub - FunctionsPersonnel Allocation Technology Allocation

Primary Secondary Hardware Software

1.1 Develop and Document Necessary Procedures Upper Management Computer Microsoft Word

1.2 Develop Effective Measures for Monitoring Quality Management System Upper Management Computer Microsoft Excel

1.3 Identify Non-compliance with Quality Control Lower Management Upper Management

1.4 Make Documents Accessible Upper Management Bulletin Board and Computer

Microsoft Word and Excel

1.5 Endorse, Review and Update Documents Upper ManagementLower

Management ComputerMicrosoft Word

and Excel

1.6 Maintain Record of Fairing Production Compliance Lower Management

Upper Management Computer


Function AllocationFunction Allocation for the Management Responsibility (2.0)



2.1 Maintain Top-down Communication with Customers Upper Management Customer

Computer, Fax Machine,

Telephone,

Microsoft Outlook

2.2 Assess Quality Management Evaluation Results Upper Management Computer Microsoft Excel

2.3 Assess Survey Upper Management Computer Microsoft Excel

2.4 Integrate Survey Feedback Upper Management Lower Management Computer Microsoft Word

and Excel

2.5 Integrate Evaluation Feedback Upper Management Lower Management Computer Microsoft Word

and Excel

Function AllocationFunction Allocation for the Resource Management (3.0)



3.1 Determine Necessary Skill Requirements Upper ManagementLower

ManagementClipboard,Computer


3.2 Ensure Staff Meets Necessary Skill Requirements Upper Management

Lower Management Checklist

3.3 Employ Training as Necessary Upper Management Lower Management

3.4 Maintain Training Records Lower Management Computer Microsoft Word

3.5 Develop Scrap Report Upper Management Computer Microsoft Word

3.6 Collect Data Upper Management Lower Management Computer Microsoft Word

and Excel

Function AllocationFunction Allocation for the Product Realization (4.0)



4.1 Document Sparton Requirements Upper Management Computer Microsoft Word

4.2 Document SMA Requirements Upper Management Computer Microsoft Word

4.3 Control the Production Lower Management Client

4.4 Handle Materials with Caution Lower Management Client

4.5 Control Measurements Lower Management Client Measuring Apparatus

4.6 Calibrate Equipment Upper Management Calibration Tools

Function AllocationFunction Allocation for the Fairing Production (5.0)



5.1 Receive Raw Materials Lower Management Computer, Forklift

Microsoft Excel

5.2 Assemble 7’ and 10’ Fairing Client Lower Management

Assembly Apparatus

5.3 Quality Control Lower ManagementUpper

Management

5.4 Tally Fairings Lower ManagementComputer,

Inventory Book Microsoft Excel

5.5 Pack Fairings Lower Management Box Tape

5.6 Ship and Deliver Fairings Lower ManagementForklift,

Transport Vehicle

Function AllocationFunction Allocation for the Measurement, Analysis and Improvement (6.0)



6.1 Administer Customer Feedback Survey Upper Management Customer Computer Survey Monkey.com

6.2 Assess Effectiveness of the Quality Management Upper Management Lower Management

6.3 Control Non-Conformity to Product Specifications

Lower Management Client Checklist

6.4 Communicate the Effectiveness of the Quality Management

Upper Management Lower Management Computer, Meeting Room

Microsoft PowerPoint

6.5 Eliminate Non-Conforming Production Procedures

Upper Management Lower Management

6.6 Prevent Errors Upper Management Lower Management

Methodology for ISO 9001 Certification

Rationale for the solution choice

Provides training specific to Upper Management, Lower Management, and Clients

Training is directed toward functional operations that are traceable to ISO 9001

Training is flexible and continuous

Assessment of Training Effectiveness

– Quantitative Measures

– Qualitative Measures

Training Manual Solution

Assessment Tools for Training

Client Training Evaluations

Client Performance Spreadsheet

Client Performance Record

Daily Communication (Briefing)

Training Program Training Manual

Training Record

Skill Assessment Worksheets

Comment Sheet

Certifications

Quick Reference Training Cards

Competency Tests

Record Audits

Results: Performance Record SpreadsheetBefore

Performance Record Spreadsheet

Client ID#

Scrapped%

Scrapped # Usable % Usable1 5 25% 15 75%2 10 33% 20 67%3 3 23% 10 77%4 0 0% 8 100%5 0 0% 8 100%7 2 11% 17 89%

Total: 20 20% 78 80%

AfterPerformance Record Spreadsheet

Client ID#

Scrapped%

Scrapped # Usable % Usable1 0 0% 18 100%2 2 9% 20 91%3 1 9% 10 91%4 0 0% 15 100%5 0 0% 12 100%7 2 11% 16 89%

Total: 5 5% 91 95%

1 2 3 4 5 6 70%

10%20%30%40%50%60%70%80%90%

100%

% Scrapped % Usable

1 2 3 4 5 6 70%

10%20%30%40%50%60%70%80%90%

100%

% Scrapped% Usable

Results: Waste Material Cost Analysis Material Cost: $0.50

Client # Scrapped Money Loss Before1 5 $ 2.50 2 10 $ 5.00 3 3 $ 1.50 4 0 $ - 5 0 $ - 7 2 $ 1.00 Total: 20 $ 10.00

Client # Scrapped Money Loss After1 0 $ - 2 2 $ 1.00 3 1 $ 0.50 4 0 $ - 5 0 $ - 7 2 $ 1.00 Total: 5 $ 2.50 $-

$2.00

$4.00

$6.00

$8.00

$10.00

$12.00

Money Loss Be-foreMoney Loss Af-ter

Results: Competency Time Analysis Training

iteration #:1 Training Time

(mins): 45Satisfactory Competency (< 10%

Scrapped)

Client # Scrapped % Scrapped Yes(Competent) No(Incompetent)1 5 25% - 12 10 33% - 13 3 23% - 14 0 0% 1 -5 0 0% 1 -6 3 30% - 17 2 11% - 1

Total: 23 21% 2 5

Training iteration #:

2 Training Time (mins): 45

Satisfactory Competency (< 10% Scrapped)

Client # Scrapped % Scrapped Yes(Competent) No(Incompetent)1 0 0% 1 -2 2 9% 1 -3 1 9% 1 -4 0 0% 1 -5 0 0% 1 -6 0 0% 1 -7 2 11% - 1

Total: 5 5% 6 1

Total Training Time (mins): 90

0

1

2

3

4

5

6

Yes(Competent)No (Incompetent)

0

1

2

3

4

5

6

7

Yes(Competent)No (Incompe-tent)

Operational Model: Typical Day Scenario

S tandRoll Fairing on

Measuring Fairng

Cutting Fairing

P oleRoll Fairing on

Thread Fairing

Fairing A ssembly

ControlB asic Quality Counting Fairing

Competent Client?T ru e

F a l s e

DocumentV erify and

SectionA rrivalE xisting C lient

Training ends

S upervisor Decision

Operational Model: Atypical Day ScenarioStand

Roll Fairing on

Measuring Fairng

Cutting Fairing

PoleRoll Fairing on

Thread Fairing

Fairing Assembly

ControlBasic Quality Counting Fairing

Competent Client?Tru e

Fa l s e

DocumentVerify and

Section

Training ends

Supervisor Decision

Client Brief Initial TrainingNew Client Arrival

Verification of Quality Management

Discussion Time constraints

Allowable time to complete project (3 months)

SMA current policies

Clients have disabilities which we were taken into account when creating a training program

SMA and its customers are in a constantly changing, and sometimes unpredictable work environment

Recommendations Implementation of Training Manual for Client and

Management

Monthly meetings to discuss Clients’ Performance

Completing monthly Fairing Production Client Evaluation Follow-up meetings with client regarding their performance and if

improvements need to be made

Completing Employee Performance Record audit monthly

Conclusions

Problem Statement

Achievements

Driven by QMS requirements to obtain ISO certification

Training manual and other deliverables

Feasibility

Implementation

Conclusion

Lessons Learned

Acknowledgement

Dr. Dahai Liu

SMA Representatives

o Brenna

o Carol

o Joanne

Implement training with deliverables

Adapt specific training of the fairing production to the other products

Address training with more focus on management

Next Steps for SMA!

Quality Management of the Fairing Production Process

Documents

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