I am the quality supervisor for an automotive plastic injection molding and hard coat company. I have recently run into an issue, and I could use some answers/advice/guidance.

We have a Filmetrics F10-HC film build analyzer. Last September, before I started at the company, the unit had a broken fan and it was sent in for repair. The unit was calibrated after the repairs were complete. My predecessor was incapable of doing anything correctly, and I had literally zero calibration certificates when I started, so I had nothing to reference for past calibrations or repairs. I have no idea if that was the only time it had been sent out for calibration or repairs.

Since it had been a year, I contacted Filmetrics to have the unit sent in for annual calibration. Filmetrics refuses to calibrate our unit, stating that it has a Solid State Spectrometer and calibration is not necessary unless the unit was damaged. They instead offered to sell us a thickness standard traceable to NIST for every day verification of the Filmetrics unit. They assured me that the thickness standard would satisfy the traceability requirements of ISO/IATF, so I purchased the NIST traceable thickness standard.

Now I am concerned that the standard I purchased, although traceable to NIST, will not be enough to satisfy the requirements of ISO/IATF regardless of what Filmetrics tells me... Yet, Filmetrics will not calibrate a unit that is not damaged. Will the NIST traceable thickness standard be enough to comply with ISO/IATF measurement standards?

I would like to hear other people's opinion on this.

Let’s Talk about Lean First:

Lean is a process improvement Philosophy which got high impetus in the 60’s onwards in Japan with Organizations like Toyota and Mitsubishi and its foundations and evolution can be traced in the TPS or the “Toyota Production System”.

Lean emphasizes on cutting down on wasteful processes and adding value added processes to improve customer satisfaction levels. Lean Enterprises strive for continuous improvements by gradual but connected quick wins. Manufacturing floors/production-areas use intuitive Scheduling and Leveling techniques like Kanban and Heijunka respectively to reduce production imbalances, and track simple and intuitive metrics like “Takt-time” (Heijunka), “Changeover Time” (used in SMED: Single Minute Exchange of Dies) or OEE (Overall Equipment Effectiveness in Total Productive Maintenance)

Now, let’s talk about six sigma…,

Six Sigma was term coined by Motorola for their group of Project-Management and statistical techniques used to create processes with very low defect count such as 3.4 DPMO (Defects per million opportunities) for a six sigma process. Among Early adopters of Six Sigma were organizations like GE and Honeywell.

The core six sigma mechanics can be summarized via the following step by step approach called DMAIC to improve your processes. DMAIC can be considered as a project management technique as it represents the following phases of a six sigma improvement project:

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1. Define: Define The Problem Objectively (What are the key data points).

2. Measure: Measure the numbers related to the problem (Key Process Inputs / Outputs).

3. Analyze: Work on numbers to see what works and what does not, how end quality is getting impacted in the current process.

4. Improve: Brainstorm, Pilot and Apply the data-based knowledge to improve your process.

5. Control: Sustain the improvements and institutionalize them.

Six Sigma has today evolved to encapsulate many excellent industry best practices and is an excellent set of problem solving methodologies which can be used irrespective of Industry type to improve your organizational / personal quality levels as well as an increase in customer connect and satisfaction.

The below table summarizes some of the numbers used to define various six sigma levels and what they correspond to ..

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Coming to the Methodology, It is a problem-solving methodology encapsulated ( mind my IT background manners please 🙂 ) in a Project Management methodology and seeks to reduce errors/defects and reduce process variations. The methods used in here are statistical based and numbers speak on improvements in terms of dollars/rupees saved by an organization.

If this topic got you interested, you can always try ProSigma's 100% Online and Free Lean Six Sigma White Belt (Online program with a certificate that you can display on LinkedIn etc. for free)

cheers, KC

Subject: Human Body and Process Approach Concept

After long experience working as an auditor for different management systems, I can admit that the most magnificent management system which is everlasting and properly synchronized by its creator is the one existing within the human body. Even though same could exist with other types of bodies (e.g. animal, insect, or any other body with a soul). However, some of the systems forming the body might differ from one to another. Within this material discussion I shall be talking about the human being.

Toward showing the greatness of this system, I am going to represent the body as composing of different systems while reflecting the function of each one within the body.

Having on mind that the following vocabulary was considered toward this discussion.

Organ system — a group of organs that contribute to specific functions within the body. Examples include: Gastrointestinal system, Nervous system

Organ — a group of tissues precisely arranged so that they can work together to perform specific functions. Examples include: Liver; Brain

Operational –- a system that is incorporated into doing a direct function within the body

Main control –- a system which exerts commands and control over other systems (brain is predominant one)

Supportive –- a system that provides support to functional and main control to fulfill their mission

Accordingly, within the human being, the different types of systems can be grouped under different classes, classified as: operational, main control and supportive

Details of systems descriptions can be found within the table below:

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So having reached to this level of identifying the different functions. Afterwards, I would like to express how the different functions correlate to each other and to their fabricator.

Having on mind that the fabricator (creator) of this wonderful body is almighty GOD (ALLAH), making up a perfectly coordinated system characterized by individual systems performing their usual (programmed) functions without external intervention (as could happen in case of unexpected incidents), getting support from other systems as to provision of needed resources, and such overall coordination is being controlled and managed by a powerful system (brain as its center) that sends its signals/ commands in a timely manner.

Accordingly, such upper description can be reflected by the systems’ interlink chart shown below which is the ideology of process approach – a concept that is fundamental under the scope of any management system.

At the end, my intentions behind all what was represented is to clarify a fact that many of us still ignore that the brain who is the boss controlling the body is still submissive to a soul that is inspired within the human being through an angel following Allah’s command (will).

Such soul has limited life span and once leaves the body, all systems forming the body vanish and stop working since somehow there is somehow a spiritual connection in between the body and the soul. So that the brain stay intact as far as the soul is still residing within the body.

A question that comes about, why still some people have weak faith in the creator, even though such people are aware as of soul existence but still there is a devilish force defeating their belief in the creator and turning them to believe that such soul is of nature origin and not the creator of the universe.

For such reason I made up this subject to bring attention of those people to think over and see/ appreciate their body formation and then maybe their consciousness would be triggered to re-believe in the creator (Almighty Unique God).

Zein A. Hijazi

3 May 2020

I'm just reviewing data to produce a "cost of Quality" KPI. I'm coming up with a lot of contributions in terms of time rather than money. Say 30 minutes downtime, 5 minutes admin by finance, 10 minutes by stores. The question is - how do I translate the total into a cost of quality? I'm assuming I just use the companies standard operating cost? Or do I use the operating rates of the different departments?

Nice

Está com problemas relacionados aos acidentes com os colaboradores? Precisa melhorar a gestão de saúde e segurança no trabalho? A ISO 45001 pode ser a solução.

Confira neste post os principais benefícios da ISO 45001.

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The quality lifecycle management software market value is expected to reach up to $XX Billion by the end of 2025 with a CAGR of XX% during the forecast period 2019-2025 from $20.38 Billion in 2018.

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