Operational Excellence: Process Reliability

We like first-pass quality as a measure of process reliability (as opposed to equipment reliability). Any loss from 100% first-pass quality obviously involves rework, adjustments, or other costly countermeasures. There are some excellent statistical tools that QC departments can use to analyze first-pass quality on a run of the mill desktop PC in real time, right on the shop floor. These tools easily determine CpK, control limits, trend analysis, out of control results, and various other methods to determine statistical process capability vs specifications.

To drive improvement in process capability, engineers must understand the critical process variables, their upper and lower control limits, the plants performance of operating within these limits, and have regular and frequent reviews of conformance to these operating limits. A straightforward method to address critical process variables that are not in conformance is to categorize exceptions in four broad categories:

- Standard operating procedures - did we do the right things?
- Quality methods, and properly calibrated instrumentation.
- Incoming raw material quality.
- Equipment reliability.

Non-conformances should be rated as to magnitude and duration, but these four categories can give a plant a quick start on the path to operational excellence via process conformance.

Synchronous LLC is committed to maintaining a continuing dialogue on operational excellence and best practices for the process manufacturing industry. To pose a question, contribute a best practice, or otherwise add to the dialogue, send a note to RobBaldwin@SynchronousLLC.com . To subscribe to our weekly newsletter send your preferred email contact address to Webmaster@SynchronousLLC.com with SUBSCRIBE in the subject line.