The Quality Assurance modules described below were created for the motor manufacturing industry. A similar quality control system could be created to meet your needs and requirements.
This Quality Assurance system was built as part of and in compliance with ISO 9000 certification requirements. Built-in requirements such as management review, documentation control and other ISO 9000 specifics have been included in other automation projects for this manufacturing plant.
· Corrective Action Database – The Corrective Action database is the “core” of the QA system. All other modules will “feed into” the Corrective Action database, sometimes automatically when certain criteria is met, and sometimes only when requested by the QA person entering data into one of the other modules. (The corresponding Corrective Action number is referenced “back” in the creating database.) When a “Corrective Action Request” has been generated, it must go through the proper steps – Initialization Form when it is first created, Response Form when the response has been received, then a Closure Form which includes the Short Term and Long Term Corrective Actions. Each Corrective Action request is given a Problem Owner, a Due Date, the Source (if generated from one of the other modules such as Receiving Inspection), who submitted the Corrective Action, Problem Description, Model and/or Part Number if relevant, and other pertinent data. This is then printed as a CA form which must be completed by the problem owner, each step creating a new form with fields to be completed. If the Corrective Action is closed “Ineffective”, a new Corrective Action is automatically created unless over-ridden by the QA person closing the Corrective Action.
· Audit Databases – There are three modules for auditing:
· Deviations – The Deviation database tracks deviations by model number/customer. Other information tracked for a deviation is Part Number, quantity run and quantity deviated, problem owner, specification violated, class of deviation (A, B or C – only A and B will automatically create a Corrective Action), and other pertinent information. At the click of a button, the database will open MS Excel™, and complete a standard Deviation form using the information entered into the database, which can then be emailed to the correct personnel.
· Receiving/Inspection Database – The Receiving database tracks the receiving and inspection of goods received, with Vendor, PO Number, Lot Number, Qty Received, Qty Defective, Qty Rejected, etc. being entered. A Supplier Inspection Report (SIR) will be created, if required, which, at the click of a button, will open MS Excel™ and complete a standard SIR form which can then be mailed. When an SIR is created, it automatically generates a Corrective Action in the Corrective Action database. When the Corrective Action is completed, some of the pertinent information is “written back” to the corresponding Receiving Inspection form – information such as Root Cause, Short Term Action, Long Term Action, etc.
· Completed Products Audit – The Completed Products Audit database is used to maintain information on all motors tested when assembled. (An established percentage of a run is tested). The tester will complete an computerized Audit Worksheet entering amps, watts, etc. There can be one of four levels of findings – Observation, Minor, Major and Critical. Reports are generated and sent to all management and headquarters. A Corrective Action is created only when the tester feels it is warranted. This database is linked to the First Piece Verification database so findings can be compared.
· Documentation Control – This database maintains and controls all ISO required documents and forms. Owners are assigned, and printing is strictly controlled and dated. Documents, forms and work instructions are created in either MS Word™, MS Excel™ or Power Point™, given a control number and revision number, and all subsequent revisions are tracked. A Corrective Action can be created when/if a document is lost.
All of the databases/modules have their own reporting features designed specifically for the needs of that particular QA function.
Call RabBoar Enterprises for more information at (479) 621-8003 or email Sales@rabboar.com.