Increase Quality with an Electronic Quality Management System

Potential Value Gains – Quality Management
Save more than £100,000 for a single recall
Reduce production waste by more than 2%
Increase First Pass Yield (FPY) by more than 5%
Reduce rework by more than 10%

Product Recalls

Fixing quality problems such as product recalls can time consuming and costly, not forgetting the damaging effects on brand reputation. It is essential that affected products are identified quickly and accurately, but eliminating these common quality problems completely and reducing the number of defect products can encourage a healthier bottom line. Quality management systems give real-time visibility and provide the historical data required to meet regulatory compliance and customer audits. An Electronic Quality Management System (EQMS) can also be used to capture and manage critical quality-related events; such as providing the capacity to involve and engage personnel in quality initiatives to improve product safety and improve recall responsiveness.

High levels of Scrap & Give Away

Reducing material waste and non value added activities is an important task when implementing quality change management. One way to cut production costs and to improve overall efficiency is to reduce the amount of scrap produced. High scrap levels can lead to high material costs and lost production time making parts which aren’t saleable. Determining current scrap rates and the main causes of scrap is the first step to managing scrap levels and setting goals for improvement. Reduced scrap levels can save time, reduce interruptions to the production cycle times – and ultimately result in the production of higher quality products first time round. Replacing paper based methods with electronic systems can significantly help reduce costs associated with high levels of scrap.

Hazard Analysis and Critical Control Points

HACCP is a recognised approach for the evaluation and prevention of hazards primarily applied within the Food & Bevarage, Pharmaceutical and Biochemical industries. It provides manufacturers with a cost effective system to control product safety, from the raw ingredients at the very beginning of the process through to the production, storage and distribution of saleable items to the final consumer. This preventative tool used within a Quality Management System improves product safety management, ensures regulatory compliance and also enhances existing automated HACCP systems. Benefits include; the introduction of automated work flows, notifications, tracking, and Standard Operating Procedures (SOPs) all of which can streamline the supply chain to increase product quality and safety.

Statistical Process Control & Process Variability

Do you have significant process variability? And, do you know what it’s costing you? Process variability in manufacturing is inevitable, and many factors can contribute to this, including; different recipes being processed on the same machine, set up times and change overs. It is important to validate these processes, you can reduce process variability using root cause analytics. Statistical Process Control (SPC) is a method of quality control using statistical methods such as visual control charts to observe the performance of production processes in order to detect significant variations. Monitoring and controlling a process ensures that it is operated to its full potential. Detecting the source of process variability will ensure that it can be changed or removed quickly; to reduce the impact of waste and the cost of production, and to produce consistent quality which conforms to customer specifications.

Mix up Prevention

Preventing product ingredient mix ups is vital to avoiding cross contamination and costly product recalls. Radio Frequency Identification (RFID), barcode technology and vision systems can be used as a tool alongside an EQMS to adopt mix up prevention techniques. Mixing incorrect raw materials and causing cross contamination can have a major impact on product safety and quality, so reducing this risk is imperative to achieving a consistently high quality product. Having a platform to monitor and manage quality issues, such as mix up prevention, can help standardise local and global quality processes in order to improve the way that quality is managed and controlled. Visibility of real-time quality information enables Quality Managers to monitor events such as material mix ups or non-conformance, therefore they can track simplify the effort to resolve such events and identify an effective resolution to reduce future events from occurring.

Yield

Having an indication of First Pass Yield (FPY) also known as Throughput Yield (TPY) metric shows how good the overall process is at producing good/correct output the first time, without having to rework items to customer requirements. It’s an important metric for measuring quality and production performance. The number of good units produced is divided by the number of total units going through the process. First Time Yield (FTY) considers only what went into the process and what went out, so is a good measure of process effectiveness, accounting for the cost of rework.
FPY is also a good measure of Continuous Improvement success, as waste and efficiency levels are analysed. It’s useful to benchmark yield performance metrics against similar manufacturing companies. Higher yields can be achieved through having the visibility and knowledge of the root causes of quality issues, so that they can be resolved quickly. Quality Management systems can be used as a tool for providing the visibility to achieve higher yields, whilst maintaining the control of waste and production processes.

Rework

Do you have rework operations? What is your current percentage and what is your goal? What would the value be if you met your goal? Focus on prevention rather than cure –  be proactive. Try reducing the cost of quality. One way to cut production costs and to improve overall efficiency is to reduce the amount of rework. Rework can result in lost time and increased work, so it is important to find out the root cause of issue, whether internally or externally (supplier) and prevent it from happening again. Rework can be caused by many things including the wrong parts being ordered, poor engineering design, lack of change management and communications. You can reduce rework by reviewing the processes in place, documenting product data and communicating any issues throughout the supply chain.

For further information about implementing an Enterprise Quality Management System please call us on 01274 599955 or email us here

 

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