With all this background, Quality Culture in the manufacturing process dates back to time, it our modern concentration has been to only comply with the discipline of implementation. While the manufacturing process of today must also be integrated with the most important, resource, and people, we have not taken these roots for granted, because pride in our nations ability to produce a quality product. It is still the highest achievable by man.
This paper will review some of the current manufacturing philosophies used in producing space-qualified electro-mechanical assemblies. It will also show the importance of using a systematic approach for defect-free manufacturing. The drive for perfection in the commercial space business requires constant monitoring of the many process parameters that can affect Reliability and Quality. Utilizing a proven low-risk manufacturing technology requires an expertise to stay competitive. Our Quality Culture Dynamics directs a new strategy in design, procurement and test. These will offer an economical alternative for meeting the customers’ specification.
In order to formulate an improvement plan you must break down these fundamental steps by data collection, analyzing and then feedback. Gathering meaningful information is a never ending process. Quality Assurance Engineering analyzes these results, by trending the manufacturing operation. The challenges are traditional and the assumptions are important and must be recognized in order to target error-free productivity. This paper will show a systematic approach for reducing the risks and focus on optimizing the problems in the manufacturing process.
The challenges of manufacturing are traditional and go back even before the advent of the industrial revolution. Manufacturing has always been on the competitive edge. That has been the requirement in building space equipment. We often hear the words “commercial” which is somewhat misleading, because compliance in meeting NASA’s (space) specifications has not been reduced. In fact it is more important to state that the instinct of a total Quality system sometimes doesn’t go deep enough.
With bold action and dramatic innovation we are becoming known as the new forward thinking society. This must be demonstrated by working together as a team, so in order to produce the wide range of products. Another words it is directly proportional and knowing what the mission objective are will guide this concept. Here is where the Dynamics of Quality Assurance Engineering comes into effect. Maintaining a competitive edge is one of the most important roles. With the narrowing market place, quality improvement requires a cultural change and that’s where Quality Engineering adds value. It is a commitment that will result in assuring compliance.
Our nation is regarded as an influential leader in the commercial space industry and with this prestigious task we have to become a value-conscious nation. This does not mean reducing requirements, but motivation a cultural change, by fostering “Cost Reductions” and developing new “Commercial Manufacturing Concepts”. Working with these requirements has to include sincere dedication for Quality, at the same time not losing sight of becoming cost-conscious with increasing productivity. This is the new resurgence tool for the 21st century and beyond.
Blending this cultural implementation with some of the older style technological principles will require change and hard consistent work. Our modern philosophy has produced many of the new space-qualified electro-mechanical assemblies, by utilizing this type of systematic approach in defect-free manufacturing. Inclusion of this philosophy will never comprise our nation’s high reliability standards. A safe environment has always been a part of this commitment.
Meeting high reliability standards is very much ingrained in all our attainable manufacturing goals. Surviving the outer space environment is first achieved by proper design standards. Manufacturing and test become the final measurement of this achievement. What must be kept in line is a consistent approach for producing a cost effective product and at the same time it must meet all of the contract methodology.
Every organization has basic goals for increasing productivity and reduces costs. What normally get overlooked are the two primary fundaments drivers. “Rework and Scrap”. These are called a by-product from a product or a service. Controlling these drivers will require an active program. This is especially true for trending to be effective. The three basic checks points of control are; Procurement, Manufacturing and Test. They have equal emphases placed on them, especially in the areas of cost reduction. The discipline of training becomes one of the common parts of this equation. Here is where the cultural implementation has to be drawn from, by utilizing some of the old style technological principles, which again are now considered new and interactive. The attention grabbing concept like “Cost Reduction” will have equal weight when setting that as a goal.
Industry fears the cost disciplines, because it requires for tracking, Rework and Scrap, but that investment is paramount for success. Saving in these basic areas will account for and can make the difference of what is considered a marginal profit line. They are normally overlooked, because “Rework and Scrap” costs can be hidden in every day operational expenses. These two factors need to be measured in the cost of Quality section of trending, because this could mean the ultimate difference between a gain or a loss. More simply put survival.
Here is the Mission (overview); all organizations have the ability to control their costs by building an alliance with the “Emphasis on Partnership”. This is the key for reducing the risks in the manufacturing process. Starting with procurement, most organizations feel this is least important, but in our modern day of schedule driven programs this has become one of the primary elements, especially in the commercial space programs, because it starts early by getting a commitment of parts in house.
It is extremely important in assuring that these parts or services come in “ON TIME”, “ON SCHEDULE” and most important “MADE TO PRINT”. Here is where the trending concepts with “Cost of Quality” get started. Then equally important comes the manufacturing phase. This requires a talented, dedicated group of skilled workers. They have to meet what is called the new flexible manufacturing processes. Skill and training with all the cultural changes become their new motivational strategy. Never losing sight of the fact that strict compliance of space specifications can not be compromised.
To stay competitive in our space community, our industry has to keep up with the basic flight requirements. Small size, Light Weight and Competitive Costs, staying flexible and meeting all of the sophisticated state art electronic requirements is the challenge. New changes come up and here is on, one recent change is the new imposed radiation requirements. This commodity adds weight and with that translates into cost. It follows many of the processes and impacts design and then manufacturing. The reason for these requirements is survival. The equipment has to be twenty years in the hostile environment of outer space. This makes compliance a very important actor.
“Commercial Space Applications” is a new buzz word, but that requires an incredibly pro-active system, with this emphasis on compliance in both the design and manufacturing operations. I call this the “Three Rings of Alliance”, [“S” + “Q” + “C”]. This equates to (“S”chedule, “Q”uality and “C”ost).
Here are some Concepts. Total Quality Management has mandated inclusion of many old disciplines, which are used to fortify a new attitude regarding an old system of control. Quality Culture Dynamics has been revived, because it makes manufacturing responsible for what it has produced.
Most organizations use some kind of Deficiency Report system. It should also be pointed out that the word “deficient” was recognized especially early in our vocabulary and its meaning has even more power today. “Labor in Vain” it is one of the most cutting definitions that affect all that hold the power of our modern competitive market place. The Deficiency Report or DR becomes the carrier of all product information.
You have to learn how to gather the trend and then per the quantity you have the analysis discipline. Plus it produces an effective realistic system that can place the emphasis on tracking all repetitive non-conforming conditions. Benchmarking is a must before resolving any of these findings.
The computer and its basic programs will make gathering information instantaneous. But it is only useful when accurate data has been inputted. Condition of the parts, assemblies or products has always been important. Another word, finding all nonconformances with instantaneous feed back regardless of complexity is the fluid dynamics of any trending program.
Directing this discipline is the role of the Dynamic Quality Assurance Engineering. Reacting with facts and getting to the “Root Cause” has to be management driven. The “Goal of Kicking the DR Habit” requires a commitment for “Correcting and Preventing Reoccurrences”. That is especially true in today’s changing market strategy, which makes it the ONLY concept of merit.
Here is a sample of a functional using the System by tracking all the elements of manufacturing operation from design to product, shipment can be straightforward. In fact this paper should not be an issue, but life has that one important element, called human nature, which by itself implies not willing to accept any type of change.
Each organization has in place many systems of control and with it Quality Assurance Engineering. That group helps to develop a discipline that starts with the design and ends up with a finished product. The ability to function within the framework of this environment must be demonstrated by establishing long term objectives. This requires a system of control, which I have experienced. Every program begins by tracking incoming parts that end up in assemblies and test.
The one type of document used to accomplish this tracking and trending methodology, has a history of my names, but I feel it equates into one fundamental form. It can be kept simple or very complex. It can be known by any name, but I call it a “Deficiency Report” or DR for short.
Fundamentally this concept has been used through many years and gathers information at various performances levels, starting at the manufacturing that cuts the chips, through the assembly plant and through all the different in-house functions.
It can demonstrate without bias how acceptable the design was through the build process, assembly and test. All these steps have on common bond, and it requires developing the proper skills and a lot of patience. Knowing that final acceptance of the part or product is the reward or I would look at it as a functional report card that measures both success and failures. Not only the design, material, process, but most important concept is the accountability philosophy.
Establishing a simple format for meeting these requirements is the goal of any tracking system. Utilizing the computer as an entry tool requires consistent information. Once that has been established evaluating product, process and/or final testing is easily accomplished. All DR’s generated can offer useful information for assessing the “Cause”, and evaluating the “Corrective Action”.
Any generation of DR’s claim to affect “Schedule”, “Quality” and “Cost”. Some organizations try to over look the main driver of this system, “Prevention” or “Re-occurrences” of the same or similar DRed conditions. This DR follows all events and reports on all the process steps taken. It is used to collect trend data from machines to humans. Sometimes it is looked upon as a burden on procurement, manufacturing and test. Here is the function of the Quality Assurance Engineer, come to play.
But the accuracy of information allows some valuable pay backs, because it can identify what the real “Cause(s)” are. The question most organizations ask, has “Corrective Action” been effective? Or more important has the “Cost” been reduced by “Preventing New Defects?” These are management type questions. They want know if their operation was truly profitable and efficient.
“Cost of Quality” becomes intergraded with true accountability for Trending all processes, but what is equally important, it must be recognized as an “Effective Cost Reduction Tool”. A word of caution, these can only represent data that has been accurately entered. Here again id were the Dynamics of the Quality Assurance Engineering plays an especially important empowered role.
The final Conclusion of this Quality Culture Dynamics paper, to make things work it requires establishing a weekly routine for data entry; it becomes paramount and necessary for accurate analysis. Issuing weekly status reports for awareness is the key for success. At least a minimum of two cancers need to be addressed regularly by a senior management committee.
It is not the mechanics of the system that will fail, but what happens with the data once generated? If it goes into a file or saved in binders, all will be lost. Any system is only as strong as its weakest link and without follow up say daily, weekly or at least monthly. With out this consistent drive, it will result in failure of the main objectives, “Cost Reduction”.
The word Quality will have little meaning if only used to express a pride without commitment. Understanding that the easy way is not always the Quality way, nor should it be the hard way. It has to be used EVERY DAY, EVERY WAY. All organizations must be compelled these types of disciplines, but without accountability for its success or failure it will only become just another system.
I would like to close and leave you with something I read in the local newspaper. “Manufacturing to feel brunt of defense cuts”. Here is the real challenge for many of our nation’s organizations. Successes will measure our ability to adapt and survive. This will require dedication and the application of our own “American Standard Quality System”, which now has many new titles, but all that was ever required was using a system proportionally and under some type of consistent control. Allowing the complexity of the products produced to guide the best function system that will give positive results.
We as Quality professionals need to always keep in the spirit of matching the highest attainable reliability that is commensurate with our mission objectives by following our Quality Culture Dynamics.
Quality Culture Dynamics © 2015 Joe Vojt
