Quality Manufacturing at GKN Aerospace Chem-tronics Inc.
A Supplier's Perspective

Contents
Process Certification
Operator Acceptance Program (OAP)
Statistical Process Control (SPC)
Certified Supplier Program
Quality Systems Audits
Material Review Board
Office of Continuous Improvement (OCI)
Summary

It Starts with Quality  We recognize our responsibility as manufacturer, fabricator, and processor to fully comply with all contractual provisions and governing regulatory requirements. To this end, have developed a comprehensive Quality Management System. The system establishes controls throughout the entire material processing cycle from proposals and bids to product delivery. It also assures that we meet quality objectives and minimizes the possibility of compromises, which could affect product quality, safety, and reliability.
Our Quality Management System is certified to the requirements of ISO 9001, International Organization of Standardization. Our system is described in three levels of documentation: Quality Policy Manual; Systems Procedures; and Operation Manuals, Departmental Procedures, and Operation Sheets. These procedures provide the required details for implementation.
Many companies are benefiting from the advantage of doing business with firms that are registered to ISO. They realize that performing quality systems audits of suppliers that are certified to ISO is redundant and a waste of valuable resources.
By accepting this third-party accreditation, there are immediate cost savings to them. We encourage all our customers to consider the cost savings available when doing business with Chem-tronics, an ISO 9001-Certified Supplier.
We certify the quality and conformity of every component from receipt of an order to the finished product using the most current tests and inspection methods provided by a proven quality management philosophy based on lean practices. Quality Engineers, Manufacturing Engineers, and Production Technicians participate in the review and evaluation of our manufacturing methods and inspection data to continuously improve efficiency and achieve the highest product quality possible at the lowest costs.
We have won numerous supplier quality excellence awards from our customers and have introduced tests, inspection, and acceptance techniques such as Operator Acceptance, Process Certification, Statistical Process Control, and on-machine inspection of "key" characteristics to ensure that all products meet the high quality standards demanded by each customer.
Vertical integration of CAD-CAM design and production functions allows our engineers to determine the most optimum design, material, and fabrication methods suited for each product. Then, using our machining, assembly, and tooling capabilities together with special processes such as chemical milling, welding, (E.B. TIG, Plasma, MIG), forming, heat treat, coatings, metallurgical and nondestructive testing capabilities, we are able to manufacture the total product under one roof.
Our NADCAP (National Aerospace & Defense Contractors Accreditation Program) accreditation in all of our special processes (stated above) continues to provide our customers the opportunity for significant cost savings. As with the ISO approvals mentioned previously, customers that accept the NADCAP accreditation no longer perform their own independent audits of our company.
Acceptance of this third-party audit(s) has eliminated redundant audits, travel, and personnel expenses. We urge all of our customers to consider the cost-savings opportunities available when doing business with Chem-tronics, a certified NADCAP--approved supplier for all special processes.

Process Certification  Our goal is to have each of our manufacturing processes perform to a six sigma quality level. To this end, we have employed numerous quality tools of which process certification plays the primary role. The main focus of process certification is the identification and control of key process inputs. This will result in the manufacture of products that are assured to meet the quality standards defined by each customer and assure elimination of costly MRB systems. Process Certification is a powerful quality tool that consistently guarantees perfect parts. We know that processes that are performed error-free will result in higher first time yields, increased productivity, and lower costs. Numerous initiatives interface with process certification and are defined under the following titles:

Poka-Yoke
Poka-Yoke is mistake proofing. Mistake proofing is a technique we utilize to control attribute inputs/outputs. Control of these types of inputs is a necessity to achieve process certification.

Kaizen
When applied at Chem-tronics, Kaizen means continuous improvement involving everyone - managers and operators. Kaizen focuses on meeting customer requirements through implementation of cellular layouts, reducing setups, and achieving one piece flow.

Total Productive Maintenance
The TPM program is the maintenance management of manufacturing equipment. This is accomplished through assessing equipment condition, improving equipment performance accuracy, and maintaining overall equipment effectiveness. TPM is the cornerstone to successfully achieving process certification. Without TPM, process certification and on-machine inspection cannot be successfully administered.

Process Review & Assessment
This initiative, also referred to as Process Mapping, combines the concepts of process flow-charting and Pareto Analysis. It focuses on identifying troublesome process elements that are causing reprocessing (turnbacks), identifying key process input and outputs utilizing SPC to reduce or eliminate sources of input variation. In addition, non-value added tasks are eliminated through the Systematical Approach to Value Engineering (SAVE).
Our process certification program consists of the following six (6) steps (see flowchart at right). The first step is to "Define the Process." Within this step we assure our manufacturing equipment effectiveness. Since machine toots are a primary source of process variation, the accuracy of each machine tool must be better understood by process and quality engineers, managers, and operators. There are two performance tests we utilize for periodic machine tool monitoring. The first is the Ballbar test. This tool is sensitive to many errors and can be used in many ways. Ballbar testing is now part of the ANSI B5.54 and ISO 230 standards for CNC machine tool evaluation. Working to these standards is an important part of ISO and Total Quality Management (TQM). One quick ten--minute Ballbar test will verify CNC machine performance, thus eliminating the machine as a possible source of production errors.
The ability to do quick, easy, and informative performance checks brings the following benefits to three major areas of our company:

In Production:
· Machine capability to produce parts to tolerance is quickly determined.
· Scrap caused by machined errors is eliminated.
· Prior value-added activities are safeguarded.
· Rework costs are significantly reduced.
· Process control is assured for machine operations.
· Machine performance can be instantly validated after a machine rebuild.
· Production scheduling can be accurately based on performance capabilities.
· Throughput can be increased by optimizing total machine performance.

In Maintenance:
· The Ballbar is essential when implementing a planned maintenance program to support machine certification.
· Key machine characteristics can be quickly assessed, including backlash, squareness, straightness, axis reversal, servo parameters and scale mismatch.
· Maintenance costs and machine downtime are reduced by the rapid diagnosis of inaccuracies.
· Machine wear can be detected early, allowing prevention of problems before major damage occurs. This new method of test bridges the technology gap between traditional testing methods and state-of-the-art CNC machines.

In Quality:
· The Ballbar is needed to comply with the ISO 230-1 and B5.54 standards for CNC machine evaluation.
· Following these standards helps maintain ISO status.
· Product quality is improved, while quality costs are reduced.
· Pre-process control will eliminate the machine as an error source.
· Costly part cutting tests needed to qualify machines are reduced or even eliminated.

The second performance test is accomplished with laser diagonal analysis. Both tests can be called "Volumetric Performance" assessments because the results relate closely to part quality.
Our second process certification step is to form focused certification teams. These teams consist of the manufacturing and quality engineers, manufacturing supervisors, operators, and support groups. This step focuses on training (Kaizen, SAVE, SPC, Process Cert). The third process certification step is the actual review and assessment of the selected process. This step consists of process mapping and eliminating non-value-added tasks. Key inputs/outputs are identified, SPC data is gathered and analyzed, and sources of input variation are reduced or eliminated.
The fourth process certification step is Process Control & Capability validation which focuses on achieving key process outputs that are in a state of statistical control and capable (CPK >= 1.33). This is done through monitoring inputs and outputs utilizing control charts to establish capability with a goal of Six Sigma.
The fifth process certification step is to develop a control plan. A control plan is a set of written strategies, which define the steps to maintain control and the capability of each process. The plan documents the "who, how, where and when" and is visibly posted.
The sixth and final step is to certify the process. An audit plan has been developed and implemented, inputs are in control, outputs of CPK >= 1.33 and a Total Productive Maintenance program is in place to assure continued compliance to six sigma standards.

Operator Acceptance Program (OAP)  We have integrated into our quality system the ability to control every step of the manufacturing process through our operator acceptance program, giving us the ability to provide high quality products at the lowest possible cost.
Each of our trained craftsmen is certified to inspect his/her own work. To become "certified," each craftsman must successfully complete an annual eye examination, a comprehensive written and practical examination covering our Quality System, and "hands-on" demonstration of their ability to use precision measuring instruments.
Our Internal Audit Group periodically audits all certified operators and the shop inspection department to assure continued compliance to all requirements.
Pride of workmanship, integrity, and ownership by our employees are the keys to the success of our "Operator Acceptance" program, building quality into the production cycle at every level. The numerous quality excellence awards given to Chem-tronics through the years by various customers affirm the fact that the Total Quality Management concepts in place at our company make a measurable difference in their assessment of our product quality.

Statistical Process Control (SPC)  SPC plays a major role in every aspect of our business, from our administrative offices to the manufacturing floor.
Manufacturing supervision, engineering, quality, and process craftsmen have received technical training in the philosophy and concepts of SPC.
We utilize SPC as an important tool to continuously assess the manufacturing system to reduce or eliminate the influence of conditions that cause variations in the performance of people, machines, measurement systems, material, methods, and environment. We have introduced the use of control charts which help direct process action because of their unique ability to distinguish between the two (2) sources of variation, Random and Assignable Cause.
Process certification, machine performance and capability, root cause analysis, process monitoring (stability), and reduced inspection all depend on employing the statistical techniques developed in our quality system.

Certified Supplier Program  When our customer places an order with us, we assure that the product quality, cost, and delivery do not stop within the boundaries of Chem-tronics. Our supplier base is "hand picked" (excluding customer approved suppliers) for each application. Our approved suppliers receive a comprehensive assessment of both their quality system and technical ability to successfully complete the specific task.
We rate our supplier base on three (3) aspects: Price, Quality, and Delivery.
Those suppliers that meet our requirements are considered for qualification as a "Certified Supplier." A supplier may be approved as either "certified," "preferred" or "qualified." A Certified Supplier has demonstrated a quality rating of 98% or better and is authorized to release products without reinspection at Chem-tronics. Deliveries from "Certified" Suppliers are periodically audited to assure continuous compliance to purchase order requirements. A "Preferred" Supplier is one that has demonstrated a quality rating of 96%. Products shipped by Preferred Suppliers do not require a physical reinspection at Chem-tronics. However, in addition to periodic audits, all documentation is reviewed to verify compliance to purchase order requirements. A "Qualified" Supplier has demonstrated a quality rating of 80%. All products and documentation received are evaluated for compliance to purchase order requirements.
The quality engineer defines all quality requirements on the Bill of Material (BOM) electronically. It is then transferred automatically to the supplier purchase order. Our receiving inspection verifies that all specified product quality requirements are in compliance prior to release for production.

Quality Systems Audits  Maintaining the systems necessary for ISO accreditation, NADCAP and customer-specific requirements is essential to our success. To this end, we have employed an independent quality assessment department to perform systems, product, and supplier audits to assure continuing compliance.
Each element within our Quality System is broken down into the form of an "Audit Checklist." Assessors utilize this checklist as a tool to assure compliance to requirements. All resulting corrective actions are forwarded to the appropriate director, manager, or supervisor for action.
All completed audits of our quality system are reviewed and approved by the Quality Systems Mgr., Director of Quality, and the President. All audits are available for customer review.
Products are divided into groups depending on similarity and processing. We perform a "product" audit on one part number per group per year. Each audit consists of identifying a completed product that is preferably "ready" to ship and perform a complete assessment, including a dimensional inspection of characteristics identified by the quality engineer. These include all characteristics identified as critical and major, plus as a minimum 10% of all minor characteristics. In addition, all quality detail from the customer purchase order, procurement of raw materials, certifications, planning, and processing are verified for evidence of compliance to specific requirements.
Product audits have proven to be a very effective tool in assuring systems compliance and product/process integrity. Supplier assessments are two-fold. First is the quality systems compliance, and second is the technical conformance. In most cases the supplier assessments are performed by two separate individuals; a quality systems assessor and a qualified technical assessor. We maintain qualified technical assessors for all our major processes such as NDT, welding, brazing, chemical coatings, plating, cleaning, heat treat, forming, metallurgical etc.

Material Review Board  All employees have the authority to withhold further processing of nonconforming items pending engineering disposition. All nonconformances are evaluated and dispositioned by both engineering and quality for the identification of root cause and corrective action. Each cause and corrective action (when applicable) is reviewed and approved by both the manufacturing engineer (ME) and quality engineer (QE).
Nonconformances are documented electronically. Data is monitored to identify trends and focus on true "root" cause analysis. All corrective actions specified on customer submittal documents are tracked by the internal audit department to assure implementation and effectiveness.
When determined by both ME and QE that further processing of a nonconforming item is impractical or technically not feasible, the product is held in MRB Bond secured by quality assurance. The MRB coordinator and the Director of Quality are the only individuals with access to the MRB Bond room. Examples of when further processing may be practical and technically feasible are when further processing may remove/eliminate the nonconformance or when an approved "Standard Repair Procedure" is utilized to correct the deficiency.
Standard Repair Procedures are prepared by engineering and approved by quality (and customer when applicable). These standard repairs are typically initiated for specific process-related issues such as etch leaks and tool gouges resulting from process limitations, tool breakage or unforeseen machine malfunctions. All documentation and traceability of standard repair usage is maintained on file. Some of our customers authorize standard repairs, thereby realizing the positive effects on schedules and the avoidance of added costs that are associated with the redundant review/approval cycle for individual MRB documentation submittals.
Nonconforming material trends, including rework, scrap, customer submittals, delivered faults, and quality costs are compiled and posted monthly.
A biannual summary consisting of internal audit results, customer submittals and complaints, nonconforming material trends, cost of quality reports (failure, appraisal prevention costs), internal corrective actions, supplier quality rating evaluations, customer satisfaction data, and quality policy measurements are presented to senior management to assure the continuing suitability and effectiveness of the quality management system.

Office of Continuous Improvement  Established to assure the success of our business strategy, the "Office of Continuous Improvement" defines the guidelines for successful implementation of our Total Quality Management policies. The OCI's focus is on defining critical business success factors, attaining internal/external customer satisfaction, and creating cultural change. OCI combines cultural change training and analytical techniques focused on satisfying the needs of both internal and external customers. OCI activities are integrated into all segments of Chem-tronics. They cover all functions from sales and marketing through design, production, and service after the sale. The formula for success of our OCI is effective training, effective implementation, and executive involvement.
Through our Office of Continuous Improvement the concept of quality is expanded to include not only final product appraisal, but a company-wide demand for excellence generated by cultural change. Our Office of Continuous Improvement produces cultural change by:
· Creating commitment - emphasizing the difference between being passionately committed and having an "interest of convenience" commitment;
· Instilling values that produce behaviors which will achieve our mission and vision;
· Effective communication - which establishes the foundation for verbal and nonverbal interaction, serving as a basis for interchange, both for information and in relationships;
· Empowering our workforce - enabling everyone to participate in making our vision a reality;
· Taking ownership of the process and pride in workmanship;
OCI analytical techniques include statistical process control, effective problem solving techniques, design of experiments, team manufacturing techniques, and world class planning which provide a formula for producing quality products.

Summary  Quality guides each product through our company with attention to detail and assurance of compliance. It starts with commitment. It grows with training and understanding. It assures product excellence. How do we define quality? In today's competitive environment, the answer is not simple. A straightforward paradigm of the last 10 to 15 years defined quality as "conformance to requirements." The only problem with this definition is that the requirements are subjective. Only the customer can really determine the requirements, their expectations and acceptance of the product or service provided. Every parameter of the service or product we provide is related in some way to each customer's expectations. Every variable in the material, process, and workmanship must be reviewed with regard to the final output and how well that output will satisfy each customer. The word "Quality" has no boundaries, but has many definitions that are defined by each customer who is driven by the demands of new technology and pricing pressures to move their bar of excellence higher each year. Quality ratings and their definitions are used by our customers to define a level of excellence as our performance is assessed each year. High ratings define winners -- ones who achieve a level above their competition. We're committed to win your award of excellence.

For more details, please contact the Aviation Components Sales Department.

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