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Manufacturing Best Practices: Optimizing Productivity and Product Quality

ISBN: 978-0-470-58214-5
201 pages
November 2010
Manufacturing Best Practices: Optimizing Productivity and Product Quality (0470582146) cover image
World-class tools for businesses to create their own manufacturing best practices

Providing best practices used throughout the manufacturing sector, Manufacturing Best Practices takes currently available manufacturing tools, such as six Sigma, Lean, ISO and Statistical Process Control (SPC), combined with real world experience, and shows how they can be used to create a culture or philosophy within an organization.

  • Shows that it is not the tools that make best practices, but rather the mindset that can be developed through the use of the tools
  • Provides best practices for manufacturers to pick those that are most applicable to their needs
  • Written for CEOs, CFOs, controllers, and line managers in the manufacturing sector

Manufacturing Best Practices closely examines the processes, protocols, and philosophies that are used in manufacturing so companies can create their own best practices scenario.

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Preface xi

Acknowledgments xvii

Chapter 1 Understanding Quality and Quality Requirements 1

The End Result 3

Quality 3

Quality Control 5

Quality Assurance 6

The Quality System 6

Quality Requirements and Specification Review 7

Quality Requirements 9

Final Thoughts 10

Chapter 2 Testing 11

Testing: What Is It? 11

Testing: Location, Technicians, and Training 12

Procedures 14

Final Thoughts 31

Chapter 3 Inspection and Data Handling 33

Inspection 34

Plans and Procedures 34

Data, Data, Everywhere! 43

Final Thoughts 48

Chapter 4 Calibration 49

Gauge Identification 51

Calibration Standards 53

Calibration Recall and Data Management System 54

Moving beyond the Simple Recall System 55

Out-of-Tolerance Conditions 56

Final Thoughts 58

Chapter 5 Corrective and Preventative Action and Error Proofing59

When Is Corrective Action Required? 61

Requirements for a Corrective Action System 62

Investigating and Resolving a Corrective Action Issue 63

Corrective Action Resolution 66

Error Proofing 67

Preventative Action 69

Final Thoughts 72

Chapter 6 Document Control: Ensuring Vital Information Is Available to Those Who Need It 73

Why Go to All This Effort? 74

Paper-Based Systems 75

Revision Control 76

Document Distribution 76

Uncontrolled Copies 79

Electronically Based Systems 80

Guidelines and Audits 81

Final Thoughts 82

Chapter 7 Process Control 83

How Do I Do It? 85

Identifying Key Process Variables 85

The Control Plan 87

Equipment Setup/Documentation and Verification 88

Process Capability 89

Monitoring 91

Final Thoughts 92

Chapter 8 Process Changes 93

Request Submission 96

External Communication of Changes 104

Final Thoughts 105

Chapter 9 Raw Materials, Services, and Suppliers 107

Sourcing: Raw Materials 108

Sourcing: Services 113

After Sourcing: The Start of a New Relationship 117

Final Thoughts 122

Chapter 10 Customers 123

The Start of a Beautiful Relationship 125

Accessibility 126

Contacts 127

Availability 128

Responsiveness 128

Follow-Up 130

Customer Care 130

Customer Satisfaction 133

Customer Recruitment and Retention 135

Final Thoughts 136

Chapter 11 Physical Facilities 137

Maintenance 138

The Work Area 140

Final Thoughts 151

Chapter 12 People 153

Education 155

Training 157

Mentoring 160

Empowerment 162

Employee Benefits 164

Final Thoughts 176

Conclusion 177

Appendix: Quality Requirements Checklist 179

About the Author 185

Index 187

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Bobby Hull is Corporate Systems Analyst at BGF Industries Inc., formerly known as Burlington Industries, Inc., and cofounder of Questworks Productions, a company specializing in computer training, Web site design, graphic design, staff development workshops, stress reduction workshops, quality control consulting, and auditing. In his analyst position, Hull focuses on designing and implementing quality control and business intelligence solutions for various divisions of BGF Industries, a multimillion-dollar textile company. Prior to this role, Hull spent over ten years as a senior quality engineer, coordinating all facets of the BGF quality control program, including the redesign of several quality subsystems to meet the requirements of ISO 9001:2000. During his more than thirty years with BGF Industries, Hull has performed in the capacity of Finishing Inspector, Lab Technician, Crew Leader, and Manager of their QC laboratory. Hull holds a Doctorate of Divinity from the American Institute of Holistic Theology, Birmingham, Alabama, and has completed course work in chemistry at the University of Richmond and in Fine Arts at Lynchburg College.

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