Manufacturing Best Practices Wiley & S AS Business Series The Wiley & SAS Business Series presents books that help senior- level managers with their critical management decisions. T itles in the Wiley and SAS Business Series include: Activity - Based Management for Financial Institutions: Driving Bottom - Line Results, by Brent Bahnub Business Analytics for Managers: Taking Business Intelligence beyond Reporting, by Gert Laursen and Jesper Thorlund Business Intelligence Competency Centers: A Team Approach to Maximizing Competitive Advantage, by Gloria J. Miller, Dagmar Brautigam, and Stefanie Gerlach Business Intelligence Success Factors: Tools for Aligning Your Business in the Global Economy, by Olivia Parr Rud Case Studies in Performance Management: A Guide from the Experts, by Tony C. Adkins CIO Best Practices: Enabling Strategic Value with Information Technology, Second Edition, by Joe Stenzel Credit Risk Assessment: The New Lending System for Borrowers, Lenders, and Investors, by Clark Abrahams and Mingyuan Zhang Credit Risk Scorecards: Developing and Implementing Intelligent Credit Scoring, by Naeem Siddiqi Customer Data Integration: Reaching a Single Version of the Truth , by Jill Dyche and Evan Levy Demand - Driven Forecasting: A Structured Approach to Forecasting, by Charles Chase Enterprise Risk Management: A Methodology for Achieving Strategic Objectives, by Gregory Monahan Executive ’ s Guide to Solvency II, by David Buckham, Jason Wahl, and Stuart Rose Fair Lending Compliance: Intelligence and Implications for Credit Risk Management, by Clark R. Abrahams and Mingyuan Zhang Information Revolution: Using the Information Evolution Model to Grow Your Business, by Jim Davis, Gloria J. Miller, and Allan Russell Marketing Automation: Practical Steps to More Effective Direct Marketing, by Jeff LeSueur Mastering Organizational Knowledge Flow: How to Make Knowledge Sharing Work, by Frank Leistner Performance Management: Finding the Missing Pieces (to Close the Intelligence Gap), by Gary Cokins Performance Management: Integrating Strategy Execution, Methodologies, Risk, and Analytics, by Gary Cokins The Business Forecasting Deal: Exposing Bad Practices and Providing Practical Solutions, by Michael Gilliland The Data Asset: How Smart Companies Govern Their Data for Business Success, by Tony Fisher The New Know: Innovation Powered by Analytics, by Thornton May Visual Six Sigma: Making Data Analysis Lean, by Ian Cox, Marie A Gaudard, Philip J. Ramsey, Mia L. Stephens, and Leo Wright For more information on any of the above titles, please visit w ww.wiley.com . Manufacturing Best Practices Optimizing Productivity and Product Quality Bobby Hull John Wiley & Sons, Inc. Copyright © 2011 by Bobby Hull. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 646-8600, or on the Web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at www.wiley.com/go/permissions. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifi cally disclaim any implied warranties of merchantability or fi tness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profi t or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic books. For more information about Wiley products, visit our web site at www.wiley.com. Library of Congress Cataloging-in-Publication Data: Hull, Bobby, 1958– Manufacturing best practices : optimizing productivity and product quality / Bobby Hull. p. cm. – (Wiley and SAS business series; 29) Includes index. ISBN 978-0-470-58214-5; ISBN 978-0-470-93198-1 (ebk); ISBN 978-0-470-93199-8 (ebk); ISBN 978-0-470-93200-1 (ebk) 1. Manufacturing processes. 2. Quality control. 3. Industrial productivity. I. Title. TS183.H85 2010 670–dc22 2010031655 Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 I dedicate this work to my mom and dad, who taught me very early that perseverance, honesty, and hard work are just as important as education. My deepest, heartfelt thanks to you both. I love you. A man with blinded eyes does not see, because he cannot. A man with a closed mind does not see, because he will not. To the fi rst, the light is freedom. To the other, enlightenment is a demon. Thus is the way of the world . . . Bobby Hull 2010 Contents Preface xi Acknowledgments xvii Chapter 1 Understanding Quality and Quality Requirements ......................................................1 The End Result 3 Quality 3 Quality Control 5 Quality Assurance 6 The Quality System 6 Quality Requirements and Specification Review 7 Quality Requirements 9 Final Thoughts 10 Chapter 2 Testing ...............................................................11 Testing: What Is It? 11 Testing: Location, Technicians, and Training 12 Procedures 14 Final Thoughts 31 Chapter 3 Inspection and Data Handling ..........................33 Inspection 34 Plans and Procedures 34 Data, Data, Everywhere! 43 Final Thoughts 48 vii viii ▸ CONTENTS Chapter 4 Calibration .........................................................49 Gauge Identification 51 Calibration Standards 53 Calibration Recall and Data Management System 54 Moving beyond the Simple Recall System 55 Out-of-Tolerance Conditions 56 Final Thoughts 58 Chapter 5 Corrective and Preventative Action and Error Proofing....................................................59 When Is Corrective Action Required? 61 Requirements for a Corrective Action System 62 Investigating and Resolving a Corrective Action Issue 63 Corrective Action Resolution 66 Error Proofing 67 Preventative Action 69 Final Thoughts 72 Chapter 6 Document Control: Ensuring Vital Information Is Available to Those Who Need It ......................................................73 Why Go to All This Effort? 74 Paper-Based Systems 75 Revision Control 76 Document Distribution 76 Uncontrolled Copies 79 Electronically Based Systems 80 Guidelines and Audits 81 Final Thoughts 82 Chapter 7 Process Control .................................................83 How Do I Do It? 85