Advanced Product Quality Planning

New products for assembly are assessed for its manufacturability using a three-phase process (Identification of Customer needs & Process Development, Qualification and Customer Feedback & Product Build Endorsement) prior mass production.

Failure Mode and Effect(s) Analysis

Potential failure modes of critical assembly processes, its potential cause and effect on the next process and in the quality and reliability of the product are analyzed to formulate actions that would prevent the occurrence of these failure modes.

Statistical Process Control

Significant process and product variable (measurable) characteristics are plotted through the use of a Moving Range (MR) or Average & Range (X-bar & R) charts to control the variability of the process and/or products. 

Global 8 Discipline

Customer complaints on product and/or process failures are analyzed using a nine step problem solving approach commencing from an emergency response action that would isolate customers from a symptom even before the subsequent investigation & analysis and eventually implementing actions addressing the complaints and/or failures, validating the results, preventing its recurrence and congratulating the team.

Gage Repeatability and Reproducibility

Performed on calibrated measuring instruments used in controlling significant process and product characteristics to determine the percentage of variability contributed by the measurement system as compared to the total process variability and provide the appropriate actions based on the criteria for acceptability of its variability.

Process Control Plans

Significant process and product characteristics, process controls, tests, and measurement systems that will occur during mass production as well as the out-of-control action procedures per product critical assembly process flow are summarized in this living document to aid in the manufacture of quality products.