1. BUEN GUIDO, BSME, ASQ-CQE
QA MANAGER
CASE STUDY – 0 Defect/100% OTD SUPPLIER QUALIFICATION
NewGen Construction
2. Case Study
• New Supplier “X” has been in the Construction
Industry, known for their sophistication for
automation has new sophisticated CNC Capability.
However the machine is currently being debugged.
• Able to take raw Revit files and feed directly to their
CNC machine eliminating the need for “Shop
Drawings”.
CASE #2 – ZERO/100 SUPPLIER QUALIFICATION
What?
3. Objective
• Qualify Supplier “X” as an approved NewGen
Construction supplier.
• Products produced to obtain Zero defects and
100% On-Time Delivery at the Construction Site.
CASE #2 – ZERO/100 SUPPLIER QUALIFICATION
Why?
4. Supplier Qualification:
I. Supplier “X” System and Process Audit.
II. CNC Manufacturer & Supplier “X” sign-off
• CNC Machine calibrated
• Operating per the manufacturers
specifications, limits and tolerances
III. Prototype Sample by Supplier using CNC
Obtain ZERO Defects & 100% OTD:
I. Process Development
II. Process (Six Sigma) Capability
III. Value Stream Mapping
CASE #2 – ZERO/100 SUPPLIER QUALIFICATION
How?
5. SupplierQualification
I – System & Process Audit
System Audit:
• Quality Program or Manual?
• Non-Conforming Material Management?
• Supply Quality Management?
• Corrective Action Preventive Action Process?
• KPI monitoring?
• ISO or other Certification?
Process Audit:
• How are incoming parts processed? Incoming QC
inspection present?
• PFMEA, Control Plan, PFD?
• Measurement Systems Capability?
• Metrology Lab?
• SPC?
• Ability to measure Rolled Throughput Yield?
6. SupplierQualification
II – CNC Manufacturer & Supplier Signoff
Final signoff to bring CNC Machine fully functional
and online for Production Use.
• Files from customers (Revit, Solidworks, Pro-E,
etc.) being translated with Zero degradation in
details?
• Perform several trial runs to make a part with
known dimensions and tolerances.
• Are the parts being produced within limits?
• Is the cycle time producing the part as per CNC
manufacturers Spec?
7. SupplierQualification
III – Prototype Sample by Supplier using CNC
Submission & Approval.
NewGen request for
RFQ and submits
completed design to
Supplier
Supplier Response –
Files accepted into
CNC
NewGen Approval to
Prototype. QA
monitors prototype
process
Supplier Prototype
Dimensional Report.
NewGen QA audits
report and Supplier’s
Measurement
Systems – Gage R&R
NewGen QA
Approves Prototype
Sample
8. ZERODefect&100%OTD
IV – Process Development
• Inputs from “lessons learned from Prototype”
• Equipment calibrated for first production run
• Volume ramp up – machine limitations
identified
• In-process and final QC inspections planned
• Control Plan – reaction plans for unplanned
production disruptions
• Measurement Systems – Gage R&R
9. ZERODefect&100%OTD
V – Process (Six Sigma) Capability
Run Process
Capability Study
Drive to a Six
Sigma Capability
Measure Rolled
Throughput Yield
11. NewGen Contstruction to work with
Supplier LSS Black Belt in monitoring
performance (KPI) on a periodic basis.
Develop a learning organization (NewGen
– Supplier) that will continue to find ways
to eliminate waste by running through
“Value Stream Mapping” over again.
Continuous
Improvement
