1. Quality Assurance
Lean Presentation
September 2013

2. Last Years Outstanding Actions
• Approved Suppliers List – Increase usefulness:
Purchasing Manager is responsible for this
process and QA provide an auditing and
guidance role.
• Benefit: A more productive method of working.
• Work/Manufacture Instructions not current:
Current files updated, old files archived.
• Benefit: Files are easier to find.
• ‘Our Hub’: ATs project, which had it’s benefits
has had to be shelved due to the amount of time
which would need to be put into the upkeep and
maintenance of it.

3. FSC & ISO Updates
• Over 29 Procedure changes.
• New procedure for installations added.
• FSC Procedures added to procedures.
• Quality manual updated/up issued.
• FSC Test audit carried out by John
Freeman, issues raised and these are
being dealt with.
• JH now a trained auditor, so back to three
auditors on-site: MM, AW, JH.

4. Estee Lauder Improvements
• Implementation of Bar Code and Carton
Label Check File.
• Implementation of Document Flip File.
• Improved lighting over benches.
• Supervisors & Team Leaders are also now
carrying out spot-checks to enable us to
QC a larger percentage of our production.
• Potential to roll-out this or a similar quality
package on other projects.

5. Estee Lauder Improvement Proposals
• Load-Up Sheets: Possibly structure?
• Carton Labels: Improve checks at origin.
• Euro Code: Continued confusion and rework of
carton labels. Anticipated production date to be
input at creation.
• Client 1st
Offs: Very often we are still
manufacturing these parts when the units should
be ready for presentation. Find ways to improve.
• Benefit: Eliminate the need to re-work pallets of
goods.
• Benefit: Raise our image with the client.

6. New Inspection Report Layout
• Modified layout removed, parameters &
Notes.
• Added Description of issues and
comments & photographs.
• These changes will make reporting issues
better, especially if the report is sent to a
sub-contractor.

7. New Inspection Report

8. New Assembly First off Report
• More relevant information.
• More fields added, e.g. Installations, manufacturing issues.
• Easier to complete.
• Easier to read.
• Assembly aids section, non structured parts.

9. Old Version Assembly Report

10. New
Version

11. Assembly First Off Summary Sheet

12. Assembly First Off Summary Sheet
• Central location for Design to access
information.
• All columns are filtered to allow for search by
specific criteria.
• Allows Designers to compare multiple Report
results at-a-glance.
• Hyperlink to full list of First Off Reports.
• Benefit: An aid for Design to view pros & cons of
a particular style of unit, easily.

13. SEAWARD
Clare Hal 104 End of Line Electrical tester
• Due to one of the SPS Lighting tester LG3301 has gone out of calibration and would
have cost £715 to repair.
• The new tester has many advantages, than the old Clares testers.
• Advantages
• Smaller, easier to transport.
• Large clear full graphic display.
• Internal memory, about 6000 tests can be stored.
• Power consumption reading.
• Printer can be purchased with tester; eliminating compatibility issues with off the shelf
printers.
• As we do not flash testing any more, we do not require a switch cable any more. Only
an earth prob.
• Data can be down load to a laptop and stored, certificate can be printed off
• Labels are more robust than the current labels we use; they use thermal transfer
process and eliminate the possibility of fade and tear resistant.
• We may be able to transfer information from the laptop via wifi to another PC.
• Pass word set/ security no keys.
• Customers name could be added to test.
• Kesslers name could be added to test results.

14. SEAWARD
Clare Hal 104 End of Line Electrical tester
• Disadvantages
• Much more expensive than the SPS tester, SPS testers
about £3600.
• Will only test 220-240V units, we would need to use a
voltage converter for 110v units; which we have.
• Can only down load via cable transfer.
• We would need a laptop for down loading of data.
• Labels are more expensive £37.80 per roll(1000 labels)
• We will still need to use terminal mains lead as the new
tester has only a plug socket.
• Only has a 14 name capacity, e.g. tester identification.
• Earth bond test .

15. SEAWARD
Clare Hal 104 End of Line Electrical tester
Earth
Bond test Load
Test
IR Test

16. SEAWARD
Clare Hal 104 End of Line Electrical tester
Tester mains socket
Earth and mains box

17. SEAWARD
Clare Hal 104 End of Line Electrical tester
Test results
Test certificate.

18. SEAWARD
Clare Hal 104 End of Line Electrical tester
• Cost of Tester & Accessories £5,794.90 Ex Vat.
• Delivery Date end of September.
• Training Date early October, Half day only.
Test information, pass and fail test shown.

19. Quality Meetings
• Greater emphasis on improvements.
• Departments to display a more pro-active
approach to discussing, owning and
solving their own quality issues.
• More departments to be included; Laser &
Pcnc; Production Office and Technical will
also now be covered.

20. Photograph Area
• No adequate lighting,
very gloomy area.
• No options for change of
background colour.
• Suitable for large units.
• Not as suitable for
smaller units.
• Small units being
photographed in the
Studio, but there is no
designated area there
either.

21. Photograph Area Proposal
• To create a photographic area with:
• Adequate, fixed lighting
• Suitable for large and small units
• Changeable background colours
• Benefit: Better quality photos, to showcase
our units. A well set-up area will mean a
speedier process.

22. L’Oreal
GA Si
Launch TOD
09-
7388001FS
C3
05.08.2013
Client:
Job:
Job No:
Date:

23. L’Oreal
Xmas 2013
GA Display
09-
7356801FS
C3
06.08.2013
Client:
Job:
Job No:
Date:

24. Works Instructions
• Update existing instructions, remove extrusion
process and add to VacForming dept.
• Write new instructions, create a work
instructions called Plastics Processing Dept.
• Liaise with department heads to capture all
relevant information.

25. Card-Backed Graphics

26. Card-Backed Graphics
• A full-length FSU graphic measures 1583mm, our guillotine has a
max stop of 1550mm.
• A graphic which has shrunk, or been cut too small leaves us with
bare MDF which is unsightly and detracts from the overall effect of
the unit.
• Proposal: Find a way to eliminate the gap.
• Consider: changing how we design our FSUs, to enable us to
guillotine our own graphics (this would potentially give us an extra
day or two of drying/shrinking time).
• Consider: Printing onto styrene v cost of marker pens/tape and time
used to disguise gaps.
• Consider: Investing in a guillotine with a larger working area (this
could then also be used to catch more overflow from the Pcnc).
• Benefit: Eliminate the extra work, time and cost of using marker
pens. Improve the aesthetics of the unit.

27. ‘Un-released Parts’

28. ‘Un-released Parts’
• At risk of producing unusable parts, and
having to absorb the cost.
• Proposal:
• Marpacs to flag a part as ‘on-hold’ when
the w/o is scanned?
• Investigate what Marpacs can offer in
terms of this.
• Benefit: reduce the waste/cost of
producing incorrect parts.

29. New Internal Reject Note
• IRN generated via marpacs.
• Serial No generated by marpacs.
• IRN updated via marpacs.
• Much easier to produce statistical information.
• Much easier to read/understand.
• More tick boxes.
• Training to be give to all personnel that require it.
• Better for the environment-less waste.
• Much easier to update-via pc.
• Much easier to manage-better for ISO.

30. New Reject Note