New to Quality

4 Replies

New to Quality

Posted by Kevin Wong on Aug 12, 2019 1:28 pm

Good day all!
My names Kevin and i'm a recent ME graduate that's been hired into a quality position at a small machine shop.
The goal for the owner is to get ISO certified, so I'm doing the best that I can to implement a proper QMS.
My current question, when there is a part failure, either due to machine, or operator error, how do we record this?
Does a simple NCR suffice? The owner is looking to track these part failures and keep record for review of employee performance.

Thanks!

Re: New to Quality

Posted by Trish Borzon on Aug 12, 2019 2:25 pm

Hey Kevin - Welcome to myASQ & thanks for becoming a member.  You should post your questions on the General Board - more visibility.https://my.asq.org/discuss/viewcategory/98 

Also - take a look at the Standards board - https://my.asq.org/discuss/viewcategory/99 - lots of good information there
Enjoy myASQ
Trish

Re: New to Quality

Posted by Amanda Foster on Aug 12, 2019 3:49 pm

I have lead ISO certification for a small Integrated logistics company in the past. Recently I moved to a similar position in a small manufacturing firm. This is my first manufacturing job, so if someone else has a better answer maybe I can learn from it too. 

Two thoughts on this subject.
1. I'm not sure what you mean by simple NCR, but in my experience NCR should involve root cause analysis which should determine the cause (machine, human, other). The report from the NCR is a sufficient record, though for trending purposes (since this needs to be discussed at the ISO required management review) you may want some type of report or spreadsheet that tracks these broken down in some meaningful way.

2. Be very careful linking the QMS and employee performance too closely. You may find people trying to subvert the QMS to avoid getting in trouble when they are part of a situation that requires NCR. The QMS should not be seen as a finger-pointing or blame shaming system. You want people to see it as valuable and willingly participate.
Amanda Foster, ASQ CQA

Re: New to Quality

Posted by Joshua Wickam on Aug 14, 2019 12:22 pm

Hi Kevin,

I have over 24 years of experience in Quality specifically in a machine shop environment. To be honest with you using NCR data to evaluate people's performance is not a good practice. It implies that the people are the only input to the process, and that they make mistakes on purpose. Using this mindset, Corrective Action results in disciplinary action and the real root causes never gets resolved. They are often covered up to avoid disciplinary action. If I ever receive a supplier corrective action stating such, I would reject it. Either they did not properly get to the root cause or they have a  training root cause.  Very rare will an employee create a non-conformance on purpose. 

I recommend evaluating the goal of capturing the data. If the goal becomes to prevent issues then a data structure to capture actionable data should be mapped in order to enhance routine root cause corrective / preventative action.  Free text is very difficult to analyze, but is valuable to include with a master data structure as added information. Using the 6 M’s think about all the inputs in delivering the product.  Then drill down the processes used, and the nonconformance’s that can occur.  Create a data structure that can be easily captured, analyzed and acted upon.
A basic example:

          Machining Center ABC
                       Boring
                             Oversized
                                   Tool Break
          
            Machining Center XYZ
                              Grinding
                                     Rough Surface Finish
                                           Speeds and Feeds Incorrect

Good luck convincing the owner to use such an approach!
 

Re: New to Quality

Posted by Kevin Wong on Aug 16, 2019 11:21 am

Thank you all for the great responses! I should've put the employee performance as a a separate question.
More so for issues like tardiness and privileges given by the owner.
We're pretty lax in some cases, but certainly not in the part production aspect.

I've been using 5 Why's as an approach for root cause. I'll look into understanding 6M's as well. The owner is definitely open to suggestions for improvement, and this board has been very helpful thus far.