Embed Size (px)
DESCRIPTION
By having your document control and shop floor quality control systems tied together at the data level, this assures all your quality efforts are operating under the same best practices and use the same data. No problems will be caused due to duplication of effort or data errors. And by having one set of master data - including ERP - you can operate fully within your QMS guidelines. Read full description of this webinar on the IBS America, Inc. Blog: http://info.ibs-us.com/blog/bid/37826/Webinar-How-to-Merge-Document-Control-and-Shop-Floor-Quality-Control
Citation preview
IBS: Unified Document Control and Shop Floor Quality Control
August 2011
IBS AmericaT H E P R O D U C T I V I T Y A D V A N T A G E
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
CompliantPro
QSYS
IBS Question and Answer
The Case for Unified Quality
THE PRODUCTIVITY ADVANTAGEIBS Overview
Unified Quality ManagementDocument Based and Transaction Based
© IBS AG Slide 3
Document Based and Transaction Based
Why do you need both?
How do they work together?
What kinds of functionality do they provide?
How does it support Your Business Initiatives?
THE PRODUCTIVITY ADVANTAGEIBS Overview
FINANCE SALES & MARKETING
ENGINEERING MANUFACTURINGSHIPPING
&RECEIVING
QSYS
Quality Process Management
Health and Safety
Risk Management
Environmental
Training
Inspection Data
Inspection Planning
FMEA
SPC
UNSTRUCTURED DATA
STRUCTURED DATA
QUALITY BUS
Master Data
• Machines
• Suppliers
• Customers
• Part #’sS
SO
User
ERP
CAD
THE PRODUCTIVITY ADVANTAGEIBS Overview
What Kinds of Functionality do they Provide?
© IBS AG Slide 5
Document Control and Change ManagementCompliance ISO / Gov. / Regulating Body Real Time Inspections and AnalysisAdvanced Quality Planning/FMEAComplaint ManagementScheduling and Execution ManagementTraining ManagementCorrective Action ManagementCalibration ManagementLaboratory ManagementPlan – Do – Check – Act
THE PRODUCTIVITY ADVANTAGEIBS Overview
How Do We Support the Organizations Initiatives?
© IBS AG Slide 6
Market Share
EPS / Shareholde
r Value
Sustainability
Manage Liability
Higher Quality = Higher Market Share
Quality Systems act like levers to reduce cost
Compliance To Standards
Records, ControlsSchedules, Training and Verifiable Proof
THE PRODUCTIVITY ADVANTAGEIBS Overview
Operational Management
© IBS AG Slide 7
New Product Introduction
Asset Performance
Operating Budget vs. Plan
Operating Margins vs. Plan
Employee Safety & Asset Protection
Compliance to Standards
Increase productivity
Reduce scrap and rework
Lower Costs
Establish Plans, Controls and Train
ISO & Governmental
Integrate engineering, production, quality
THE PRODUCTIVITY ADVANTAGEIBS Overview
Users
Do Jobs Correctly
Efficiency
Know How
Safety
Input / Feedback
Work Instructions
Expertise/Training Profile
Best Practices
Videos / Graphics / Pictures
Handling and Safety Info, especially in case of an incident
Corrective and Preventative action requests
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Shop Floor Quality
© IBS AG Slide 10
Solve Quality Issues Early in the Cycle: How?Design and Plan for reliability, quality $$$$Verify Supplier QualityMonitor Production QualityUse Proven Improvement Processes Continuously:
SPCCAPAFMEAPDCA
THE PRODUCTIVITY ADVANTAGEIBS Overview
•
Act Plan
DoChec
k
FMEAControl Plan
Flowchart
Inspection Planning
Project Management
Production
Incoming Goods
Outgoing GoodsQuality Control
Panel Supplier Assessment
SPC
Problem Solving Process
Action Management
Audit Management
IBS Quality Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Overview
Act Plan
DoChec
k
Fine planning
Process Overview /Online-Visualization
KPI (OEE, FPY)Analysing (PAA, CPK)
ODA
Resource Planning
PRISMA
DB
Admin/Konfig. Koppel-PC
ACC
Koppel-SPSAndon Board
Diagnose-Touch Panel
Info-Point
Masch.-SPSMobil-Scanner
Docking-Station
Handy
Auswertung
...
LiTab
Prozess-Netz (Ethernet)
MDA
Problem Solving Process
ActionManagement
Audit Management
Order Management
PaperlessRepair
© IBS AG Slide 12
IBS Quality Execution Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS Traceability solutions for product and process traceability
Customer
Supplier
Plant 1Plant n
Transport
Purchased Parts
Standard Assembly Groups
Standard Components
TraceabilityKPI‘s
Cockpit
© IBS AG Slide 13
THE PRODUCTIVITY ADVANTAGEIBS Overview
CompliantPro at-a-Glance
DocumentManagement
Training &Qualifications
SupplierManagement
Reporting
CustomerManagement
Audits &Assessments
CAPAFDACompliance
Risk Management& SOX
Environmental
Prüfmittel-management
Health & Safety
EquipmentMaintenance& Calibration
DocumentManagement
Training &Qualifications
SupplierManagement
APQP(FMEA/ControlPlan/PPAP)
CustomerManagement
CAPAFDACompliance
Enterprise Risk Management
InspectionManagement ,Nonconformance,& SPC
Prüfmittel-management
EnvironmentalHealth & Safety
EquipmentMaintenance& Calibration
THE PRODUCTIVITY ADVANTAGEIBS OverviewSlide 15
User’s Administrator Sets Up the:
Different Document Categories
Document Templates for each Category
List of who can create Documents
Document Numbering Scheme
Review, Approval and Obsolescence Workflows
Management Escalation Procedure
Document Release Date
Restriction of Access to Specific Documents
Document Control
THE PRODUCTIVITY ADVANTAGEIBS OverviewSlide 16
Integrated Training & Qualification
• Notifies each employee that they need training.
• Links to updated documents and changing course requirements.
• Advises of any missed deadlines.
• Alerts manager when employees are deficient/ create list.
• Meets regulatory requirements for monitoring employee qualifications.
• Prevents oversights.
• Automates the monitoring function.
• Prevents assignment of unqualified employees
• Automated escalations.
THE PRODUCTIVITY ADVANTAGEIBS OverviewSlide 18
Corrective Actions & Preventive Actions Modules
THE PRODUCTIVITY ADVANTAGEIBS OverviewSlide 19
Corrective and Preventative Actions
• Configure multiple types of CARs or
PARs to meet your unique requirements.
• Allow a leader to assign a “team” to manage
Containment and Resolution responses.
• Elect to follow an “8D” or “7Step”
procedure model, or Configure your own specific
workflow for CAR resolution.
• Allow different methods of CAR creation
THE PRODUCTIVITY ADVANTAGEIBS Overview
THE PRODUCTIVITY ADVANTAGEIBS Overview
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Agenda and Introduction
Solution Overview
Company Overview
Questions?
Customer Case Studies / Benefit Analysis
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS America, Inc.
Group with 5 companies Germany, USA, Lithuania plus
China
Publicly traded since 2000 Revenue 2008: ~ $30 million
Founded in 1982 Today about 180 employees
Supporting over 4000 customer installations globally (spanning over 50 countries and 5 continents)
THE PRODUCTIVITY ADVANTAGEIBS Overview
Key Competences & Positioning
Industry independent Process consulting
Implementation
Training
Project Management
ServicesInnovativeSoftwareSolutions
Integration withcorporate
IT-Systems
MIS
MaintenanceOperationImplementation
Machinecontrol
ERP
Process control
MESCompany mgmt.
Production
Directors
Dat
a flo
w
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS Customers Save Money
The Cost of Quality as % of RevenueSource: Aberdeen Group 2009
IBS customers achieve substantial cost reductions
with better than average performance (e.g. first pass yields, on time shipments).
0%
50%
100%
IBS Average Average Laggard
18% 24% 29%
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Agenda and Introduction
Solution Overview
Company Overview
Questions?
Customer Case Studies / Benefit Analysis
THE PRODUCTIVITY ADVANTAGEIBS Overview
Thank You!
“Merging Document Control with Shop Floor Quality Control”
Presenter: Tim GambleEmail: [email protected]
Phone: 1 (781)-862-9002 x137
Read the IBS Blog for more quality resources, whitepapers, articles, and webinars: www.info.ibs-us.com
Follow Us on Twitter: @IBSAmerica
