Recent AS9100C Certifications

October was a busy month for Lean Quality Systems!

During the past several weeks, two of my clients required AS9100C certification in a very short period of time. One of the companies was Ashley Precision Machining.

Proficient in very small parts, Ashley Precision has an edge on their competition because they make their own fixtures to cut the parts. In my opinion, they are one of the most talented lathe companies I have ever seen!

Ashley Precision is currently expanding into the aerospace industry because a few major aircraft manufacturers noticed their capabilities with regards to CNC turning of small parts, and asked the company to become AS9100C certified.

It was great to work with them because they didn’t have any systems in place. Starting from scratch is a blessing for consultants, because we don’t need to undo any bad habits! We completed AS9100C certification last week!

In commenting on my efforts in assisting Ashley Precision in achieving AS9100C certification, the company’s president, Robin O’Donnell, said:

“I truly believe that you are a guardian angel! We cannot thank you enough for all the help in setting up our job planning mechanism to help assure that our customer requirements are being met, and for your guidance in making it possible for us to become AS9100C certified by NSF. I have already shared your name with other organizations, and we are delighted to serve as a referral source. Thank you again for your professionalism, and more importantly, your friendship throughout this process.”

Another client, Abbott Technologies, was an existing AS9100B certified company, but was looking to upgrade to an AS9100C system to streamline a complicated administrative system. Similar to my work with Ashley Precision, I was able to help Abbott achieve AS9100C certification in record time!

Join me in Anaheim at the 2012 ASQ World Conference on Quality and Improvement

I am pleased to share the news that I have been chosen as a presenter at the 2012 World Conference on Quality and Improvement which will take place in Anaheim, Calif. at the Anaheim Convention Center, May 21-23, 2012. The event is sponsored by the American Society for Quality (ASQ).

My session is on the topic of “Risk Management,” and I will be looking at some of the new AS9100C requirements that are part of the changes that have been made to ISO 9001:2008.

Section 7 of both standards relate directly to the “worker bees,” or what we as companies do to produce a product or provide a service.

In the revised standard, and in Section 7, we find the mitigation of risk to be the primary focus, and a consistent theme that is relevant to employee training, suppliers, materials, production, product handling, packaging, shipping, delivery and feedback from our customers.

In AS9101D, the Audit Requirements for AS9100C, a few questions are asked of the organization:

  1. What are your risk management responsibilities?
  2. What is your definition of your risk criteria?
  3. How do you identify , assess, and communicate risk within your company?
  4. How do you identify, implement, and manage the actions to mitigate risks that exceed defined risk acceptance?
  5. Do you understand the remaining risks after mitigating actions?

My presentation at the World Conference on Quality and Improvement will offer an interactive session that will analyze specific items, situations, the probability of risk that may occur, the severity of the results if it fails, and what we can do to mitigate its effect on people, the environment and equipment. We will then classify our conclusion with a “Risk Priority Number and Severity” code.

I hope that you will consider attending! I will be presenting on Monday, May 21 at 3:00 p.m.

AS9100C: Evolving to Align with the Globalization of Aerospace

Occasionally, I write for several industry trade publications including NDT Magazine and Quality Magazine. This month’s issue of NDT Magazine features my article on AS910oC and how the standard has evolved to align with the globalization of aerospace.

Here is a brief excerpt from the article:

As a prerequisite to guarantee compliance with AS9100C, aerospace engineers must understand why the AS9100 standard was modified with the revisions present in its current version, “C.” Recent revisions to the ISO 9001 and AS9100C standards, as characterized in ISO 9001:2009 and AS9100C, expand and define the need to control Risk, Critical Items, and Key Characteristics. Also covered under these revisions is the need to possess a better understanding of Configuration and Risk Management. 

If you are able to understand both “the intent” and “the definition” of these key-additions to the AS9100 standard, you will know when you are making a right decision to add or delete processes and requirements within your operations. 

First, we must understand why changes were necessary to the AS9100C standard. The rational behind these changes, as stated in AS9100C, is the revision of the standard to incorporate the requirements of ISO 9001:2008, which was updated as a result of the challenging times inherent in today’s global business environment. 

Globalization of business has led to great diversity in regional and national requirements. Over the years, we have evolved from an industrial nation to a service industry, and our expectations have complicated our objectives. Outsourcing has become a business practice for many manufacturers of aerospace, medical device and other products. Business models are no longer based on the development and manufactured products, from start to completion. Rather, companies that were once manufacturers have become importers or “kitters.” 

Kitting is a business model that relies on parts that are imported from all over the world, that are assembled, often by a third-party located offshore in Central and Latin America or Asia Pacific. The assembler will then affix the so-called manufacturer’s logo before the product is sold into the marketplace. 

All of these processes must be managed properly, which creates new and exciting challenges that require discipline and commonsense to properly define responsibility and authority without compromising customer, statutory and regulatory quality management system requirements.

For the complete article, please click here. If you like this article, please remember to share with your networks through Facebook, Twitter and LinkedIn.

Quality Management and Information Technology: Is Your Company Leading, or Following the IT Department?

One of the first things I like to do in when I take on a new client is to visit the company’s IT department.

Over the years, I have discovered that CEOs value Information Technology (IT) managers more than any other manager within the company. The reason for this? Most CEO’s have no idea what IT does most of the time, this department is often viewed as the one organization within the company that can save the day when computers crash, systems need debugging, or viruses need to be eliminated. Most of the time, IT departments are tucked away behind locked doors, not to be seen from or heard from until a computer problem is reported, then it is “Super IT” to the rescue!

This begs the question, how much of the computer system do we really need? Are you a major corporation networked to the world, or a small business with 25 employees? IT is a valuable component to any sized company, however, I feel that sometimes, companies give too much responsibility and authority for the fragile IT systems is given to IT personnel.

In most companies, about 25% of the employee computer time is used for personal use. The fact is that most workstations don’t even need computers. Many are simply micro managing real-time work hours. Who cares if 25% of an hour is lost? It always works out to the same amount of time to produce a product. Sometimes minor problems occur and time is lost, but sometimes there are no problems and production finished ahead of schedule.

For example, for many years now, one of my defense clients has had a consistent turnover time for refurbishing communication equipment for United States Navy ships. Documented to the time to replace each component, this process cost hundreds of thousands of dollars to establish, and hundreds of thousands of dollars to maintain. After 9/11, there was a rush to get the fleet underway with a backup for each communication system. This meant that every piece of communication equipment had to be repaired, refurbished and installed or shipped pronto! When I reviewed the records, I found that production increased by a whopping 500%. This needs no explanation, the bottom line is that when driven and motivated to perform, a workforce can make or break a company.

The limitations for production are placed on the workers by the management system. Management systems think they establish the time it takes to a job, but the time to do the job is measured the worker. Workers are not dumb. They always outsmart management because they come from a different mind set than the manager. The worker is in a survival, family protection, and breadwinner mode.

Most workers operate based on fear, i.e. fear of work layoffs, fear of working to hard and finishing before the shift ends, fear of working themselves out of a job, or fear of anyone else knowing the details of what they do to produce a good part.

A correct and just workstation is important, but not a workstation being told they lost 10 hours of production last month. Personally, I have encouraged many companies to remove computers from workstations, and remove time limitations on production. If you have Capability Maturity Model (CMM)-driven equipment that is one thing, but if you don’t, most of the computers are simply causing more work interruptions, rather than supporting work production.

Point To Ponder

Are you at the mercy of IT, or is IT another department under your leadership?

 

 

What’s That Smell?

At home, if we do not clean out our refrigerators or our food storage cabinets, after time, we will undoubtedly smell something going bad.

In companies, it is no different. Every time I enter a company for the first time, I can almost smell the trouble brewing. Perhaps “smell” is a strong word, but I can definitely sense problems. The signs are there by the looks, or lack of looks, I receive from the employees as I enter their assigned work space. In some cases, I may get the “What did I do now?” look, or “Great, they Know What I did!” look. One of my favorites is “If I can stay still and not make eye contact, they will not know I’m here” look.

Body language in companies tells quite a story about the stability of a company’s management system. Recently, I was dealing with a Quality Assurance Manager who, with his most serious face, explained to me how every person in the company was not following his procedures. He also used every quality acronym ever written in his explanation. I think that this was mostly to assure me he read all the books about quality management systems. After my tour of all the departments in his company, only one person made eye contact with us, and it was the “What did I do now?” face.

After the tour, a feeling of anger at the management and pity for the employees, suddenly came over me. Yes, this company stank of outdated cheese, milk, meat, and whatever else was rotting within the ranks of the company’s employees.

How does this happen? Most often, it boils down to “The Peter Principle.” As stated in the book of the same name “In a hierarchy every employee tends to rise to his level of incompetence.” (Source: Dr. Laurence J. Peter and Raymond Hull, The Peter Principle. Souvenir Press, 1969).

How does a person rise to their point of incompetence? Some people are Duck People, some people are Eagle People, and some people are Rabbit People. You are a Peter Principle person if you assume that a good floor worker (Rabbit) can be a good manager, and soar like an Eagle without training, experience and the inherent ability to lead. You cannot train a Rabbit to swim like a Duck, a Duck to soar like an Eagle, or an Eagle run like a Rabbit.

My 20 years in the military gave me the opportunity to combine my Italian Jersey City survival street skills with the systematic approach, which guided me from Apprentice to Chief Petty Officer and a NAVSEA Level III Examiner and Instructor in Management Systems. What this did for me was to help me recognize where my strengths and weakness lie in my leadership skills. Personally, I have a lot of trouble tolerating complacent employees, or employees who do not care that their decision caused collateral damage to other employees or departments. I am best suited as a consultant who can go into a company, identify the problem, call a duck a duck, set my sights on the problem and remove the problem while training a new style of employee. I do not have any allegiance with any of the employees, so my motivation is only for the good of the company as an integrated system. And, while the employees love it, the managers either love me or hate me, no in-between.

Every company needs to clean its refrigerator on a regular schedule. How do we do this? With an outside assessment from an impartial consultant with no affiliation to middle or lower management. The consultant must be hired by the CEO, president or owner to assess the following:

1.)      Company Vision and Goals – Long and Short Term

2.)      Managers Job Descriptions – Clear Statements of Primary and Secondary Responsibilities

3.)      Manager and Lead Lines of Responsibility and Authority – Clear, Defined and Followed

4.)      Leadership Effectiveness – Is the Peter Principle active in the company?

5.)      Perform a Short Gap Analysis – To identify the Problems and Recommend Adjusts to put the train back on track.

What’s in your refrigerator? Can I help your organization get back on track?

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