9780470582145

World-class tools for businesses to create their own manufacturing best practicesProviding best practices used throughout the manufacturing sector, Manufacturing Best Practices takes currently available manufacturing tools, such as six Sigma, Lean, ISO and Statistical Process Control (SPC), combined with real world experience, and shows how they can be used to create a culture or philosophy within an organization. Shows that it is not the tools that make best practices, but rather the mindset that can be developed through the use of the tools Provides best practices for manufacturers to pick those that are most applicable to their needs Written for CEOs, CFOs, controllers, and line managers in the manufacturing sectorManufacturing Best Practices closely examines the processes, protocols, and philosophies that are used in manufacturing so companies can create their own best practices scenario.

Bobby Hull is Corporate Systems Analyst at BGF Industries Inc., formerly known as Burlington Industries, Inc., and cofounder of Questworks Productions, a company specializing in computer training, Web site design, graphic design, staff development workshops, stress reduction workshops, quality control consulting, and auditing. In his analyst position, Hull focuses on designing and implementing quality control and business intelligence solutions for various divisions of BGF Industries, a multimillion-dollar textile company. Prior to this role, Hull spent over ten years as a senior quality engineer, coordinating all facets of the BGF quality control program, including the redesign of several quality subsystems to meet the requirements of ISO 9001:2000. During his more than thirty years with BGF Industries, Hull has performed in the capacity of Finishing Inspector, Lab Technician, Crew Leader, and Manager of their QC laboratory. Hull holds a Doctorate of Divinity from the American Institute of Holistic Theology, Birmingham, Alabama, and has completed course work in chemistry at the University of Richmond and in Fine Arts at Lynchburg College.

Preface	p. xi
Acknowledgments	p. xvii
Understanding Quality and Quality Requirements	p. 1
The End Result	p. 3
Quality	p. 3
Quality Control	p. 5
Quality Assurance	p. 6
The Quality System	p. 6
Quality Requirements and Specification Review	p. 7
Quality Requirements	p. 9
Final Thoughts	p. 10
Testing	p. 11
Testing: What Is It?	p. 11
Testing: Location, Technicians, and Training	p. 12
Procedures	p. 14
Final Thoughts	p. 31
Inspection and Data Handling	p. 33
Inspection	p. 34
Plans and Procedures	p. 34
Data, Data, Everywhere!	p. 43
Final Thoughts	p. 48
Calibration	p. 49
Gauge Identification	p. 51
Calibration Standards	p. 53
Calibration Recall and Data Management System	p. 54
Moving beyond the simple Recall System	p. 55
Out-of-Tolerance Conditions	p. 56
Final Thoughts	p. 58
Corrective and preventative Action and Error Proofing	p. 59
When Is corrective Action Required?	p. 61
Requirements for a Corrective Action System	p. 62
Investigating and Resolving a Corrective Action Issue	p. 63
Corrective Action Resolution	p. 66
Error Proofing	p. 67
Preventative Action	p. 69
Final Thoughts	p. 72
Document Control: Ensuring Vital Information Is Available to Those Who Need It	p. 73
Why Go to All This Effort?	p. 74
Paper-Based Systems	p. 75
Revision Control	p. 76
Document Distribution	p. 76
Uncontrolled Copies	p. 79
Electronically Based Systems	p. 80
Guidelines and Audits	p. 81
Final Thoughts	p. 82
Process Control	p. 83
How Do I Do It?	p. 85
Identifying Key Process Variables	p. 85
The Control Plan	p. 87
Equipment Setup/Documentation and verification	p. 88
Process Capability	p. 89
Monitoring	p. 91
Final Thoughts	p. 92
Process Changes	p. 93
Request submission	p. 96
External Communication of Changes	p. 104
Final Thoughts	p. 105
Raw Materials, Services, and Suppliers	p. 107
Sourcing: Raw Materials	p. 108
Sourcing: Services	p. 113
After sourcing: The Start of a New Relationship	p. 117
Final Thoughts	p. 122
Customers	p. 123
The Start of a Beautiful Relationship	p. 125
Accessibility	p. 126
Contacts	p. 127
Availability	p. 128
Responsiveness	p. 128
Follow-Up	p. 130
Customer Care	p. 130
Customer Satisfaction	p. 133
Customer Recruitment and Retention	p. 135
Final Thoughts	p. 136
Physical Facilities	p. 137
Maintenance	p. 138
The Work Area	p. 140
Final Thoughts	p. 151
People	p. 153
Education	p. 155
Training	p. 157
Mentoring	p. 160
Empowerment	p. 162
Employee Benefits	p. 164
Final Thoughts	p. 176
Conclusion	p. 177
Appendix: Quality Requirements Checklist	p. 179
About the Author	p. 185
Index	p. 187
Table of Contents provided by Ingram. All Rights Reserved.

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Manufacturing Best Practices : Optimizing Productivity and Product Quality

Manufacturing Best Practices : Optimizing Productivity and Product Quality

0470582146

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