Manufacturing Process | Quality Engineering | Problem Solving | Continuous Improvemnet | Human Factors

Quality Engineering starts with the concept of improving the process / system by which products are produced. Quality improvement is a continuous, never ending activity. The workers involvement, ground zero decisions and knowledge on actions needed are essential. The customer is the criterion of quality.

DOE is a very powerful tool to solve chronic quality/process/design problems, utilizing line workers brain, optimizing specifications and tolerances, optimizing and characterizing products and processes, and reducing variation from part to part. Quality improvements range from 10 to 1000 folds and can be achieved in a systematic manner.

DOE helps to achieve quality excellence (indirectly business excellence) in the areas of problem solving, ROI improvement, customer loyalty, reliability improvement, cycle time and cost reduction, supplier, design and process improvements. DOE is a total quality tool and make a success where other tools such as six-sigma, TQM, ISO 9000 failed. Any DOE study should start with process capability (Cp). Cp is the measure of spread and Cpk is corrected for non-centering, which is a better measure of variation and process capability. To make Cp and Cpk meaningful the specification limits have to be correct. The sources of error can be product, process, raw material specifications, poor manufacturing practices, poor suppliers and/or operator errors.

We utilize various clue generation tools such as multi-vari, components search, paired comparisons or product/process search to generate variables. By variable search we identify the root cause variable. Using B vs C method we validate the variable. The gains are safe guarded with positrol method and maintain with pre control charts.

By following above systematic criteria we have solved many chronic quality problems for our clients.

SPC is an effective method for discovering many conformance problems. It is a monitoring and maintenance tool, which freezes the gains of good process. SPC starts with positrol chart. Pre control charts will be developed.

We help to monitor your processes statistically in the simplest way, on a day-to-day basis.

QFD (Quality function deployment) is capturing customer voice into the new design or product. It works on the tool “house of quality”. QFD translates customer requirements to engineering specifications to process and test requirements. It improves communication and prioritizes improvements. It also improves process reliability with targeting cost reduction. Its goal is to satisfy more customers and thereby increase the market share.

We help develop the necessary charts to deploy QFD in your organization to impact your product and/or services.

We do quality audits in a new and revolutionary approach. Instead of doing an audit against a document, we audit the purpose of the documents and its creation. Most of the times, the root cause of the quality problem lies in the documentation system. We check the background of the procedure or document and evaluate how they fit in the present manufacturing system. If necessary we help to create a new proven system.

We also help in your supplier’s identification, qualification and periodic auditing to ensure continuous reliable supply.