First Edition Dated September, 2000 19
the full range of process improvement tools in meeting this
requirement.
6.1 Process and Product Analysis
A thorough analysis of the product and the associated processes should be
performed using the tools described in D1-9000-1, AQS Tools. Some of the
tools typically used include team brainstorming, flow charting the
manufacturing process, collecting production data (e.g., defects, scrap and
rework), collecting engineering information (e.g., specifications and drawing
datums) and performing a risk analysis. Additionally, techniques such as
Value Stream Mapping can be applied to assist in the correct identification
and prioritization of improvement opportunities.
In addition, the tools can be used to solve problems and improve processes
and products. For example, performing Pareto analyses of defects, scrap,
rework or waste can highlight specific problem areas where quality
improvement resources can be focused. Furthermore, the problem analyses
can help identify whether quality problems are caused by mistakes (e.g.,
mismarked parts) or are due to excess variation. Many of the problem
analysis tools can be used to reduce or eliminate both quality mistakes and
variation.
6.2 Improvement Activities and Projects
Selecting Improvement Activities
After a systematic analysis of processes and products, the supplier identifies
and prioritizes improvement activities and projects. The emphasis of these
projects should be on improving processes that affect the company and its
customers. Any improvements made should be reflected in the performance
measures, including those identified through Section 4.1.2 of Addendum 1.
Properly constructed performance measures can sometimes lead directly to
specific improvement projects. “Triggers” can also help identify improvement
areas. Examples of triggers for improvement activities include the following:
Scrap
Rework
Reinspection
Defects/escapements
Repairs
Excessive flow time
Assembly problems
Late deliveries
