Component & Large Scale Assembly - Quality

Your Situation

Documenting the non-conformance.
Aerospace's AS9100 QMS Standard requires you to maintain a complete record of all nonconformances. Whether the anomaly is a simple, minor or major; thorough documentation is essential--compliance is not optional. Now think about how long it takes to complete your nonconformance forms--dozens of boxes to check or fill in, no matter the size of the anomaly.

Intercim's answer

Emergent Process Management, or EPM, is a variable flow process engine that is fully compliant with AS9100 regulations. EPM handles all unplanned product or process anomalies including non-conformance and corrective action. Depending on the severity of the event, EPM will adjust the data-entry requirements, yet won't let you fail to enter required data.

Your Situation

Non-conformance collaboration across highly engineered, complex processes.
A nonconformance is discovered in final assembly. The mission-critical component is used not only on this unit, but on four variations across the fleet. Whether you call it Multi-Unit or Quality Alert processes, purging or a recall; resolving a problem across multiple processes can be daunting.

When it's discovered that a problem on one unit could affect others, EPM can track and constrain identified parts until the scope of the problem is determined. Automated distribution of the disposition plan significantly speeds up the time between problem discovery and resolution. Multi-unit EPM tracks problems in each unit separately throughout the product lifecycle--from assembly to post delivery.

Intercim's answer

If everything ran smoothly 100% of the time, there would be no exceptions…no re-work…no scrap and no such thing as a nonconformance. Because this level of perfection doesn't yet exist, Intercim created and coined the term Emergent Process Management (EPM).

EPM is a configurable variable process workflow engine that enables efficient and effective disposition of any unplanned or non-standard product or process event. These events can occur on the shop floor or other points throughout the supply chain. In the quality arena, EPM:

• Incorporates nonconformance management into the execution system with the capability to constrain work until the issue is resolved
• Corrective action processing can be triggered by a nonconformance and linked to that or other nonconformance records
• Follow-up ofEffectiveness triggered from, and linked back to, corrective action provides closed-loop nonconformance process required for ISO Certified manufacturers
• Manages varying MRB review processes

Although EPM was originally developed for quality professionals, the system's benefits are reaching far beyond the QA department. EPM today is being used to track developmental or temporary parts not yet certified as flight-worthy, managing unit or aircraft airworthiness certification and supporting the supply chain with source inspection documentation.

Your Situation

Last week's cycle times were 16% greater than this week. Upon reviewing the Performance Tracker dashboard, you learn that 18 parts are behind schedule because of open non-conformances with incomplete corrective actions.

Drilling down further, you see that a best practice rule was defined to correct these types of anomalies requiring some rework using a specific tool. Because that tool is unavailable, corrective action could not be completed.

Intercim's answer

Best operational practices, also known as rules, are based on historical data. With constantly changing variables such as labor, production schedules and quality, it becomes necessary to continually monitor, analyze and update these rules.

Displayed in a dashboard format, the Pertinence Suite Performance Tracker aligns best practices with actual production metrics and alerts users of any drifts or inconsistencies.

Additionally, users on the shop floor and the management suite can review important metrics like first pass yield, cycle time, non-conformances or other operational statistics. This information is vital in confirming KPIs are being met and to affirm strategic direction.