Author Archives: Reliability Solutions

Maximising Supply Chain Quality with a proven model

Supply Chain Quality is a very important area as companies cannot only rely on simple Audit, Incoming Quality Control, etc. to manage suppliers. Supplier visits / audits are all well and good, but do they truly bring sustainable quality improvement? 

As companies strive for ongoing cost reduction a much more detailed and ‘real-life’ awareness of supplier capability is imperative to minimise risk of changing suppliers or making major changes with existing ones. The key to improving Supplier Quality is developing a sequential set of detailed activities that clearly ‘reveal’ supplier’s true capability and provide suitable process reporting that clearly demonstrates a supplier’s ability to produce consistently high quality components / sub-assemblies / products.

Setting up a new supplier or even changing management approach to existing suppliers requires the supplier QE to have a ‘toolkit’ to lead them through a proven and efficient method of maximising supplier quality and providing long term assurance via ‘virtual’ reporting.

Reliability Solutions have developed a very effective ‘6 Step Supplier Process’ which has been used widely across many clients, leading to major reduction in supplier failure levels in all stages of the client’s manufacturing process and in the early life stage of end customer usage.

Step 1 Complete the Reliability Solutions Quality Questionnaire from which the SQE will score response to decide if supplier is even worthy of a visit.

Step 2 – Supplier provides requested specific information / data in advance of site visit following Step 1 approval in line with Questions asked.

Step 3 – Review Supplier process in detail and apply the Reliability Solutions Audit procedure with scorings applied and grading of supplier on completion, perform the Reliability Solutions ‘SMART’ scoring of supplier.

Step 4 –  Perform the Reliability Solutions Supplier Reliability Maturity Index rating which focuses on Engineering related capability and Reliability focus which will highlight risks in longer term reliability and ultimately warranty performance.

Step 5 – If steps 1,2,3,4 completed successfully, supplier will provide samples for Customer review and testing which will include a range of robustness, durability, function and  reliability stress tests (mostly for electronics) will take place.

Step 6 – Supplier now ready to start production. At this point the Reliability Solutions 6UP management reporting (discussed with supplier in step 2),will be implemented at supplier for ongoing  reporting direct to the supplier QE.

In each of the above steps, many years of experience has been used to develop the 6 step approach that provides measurable outputs the supplier QE uses to benchmark suppliers and also drive continual improvement at existing ones.

Within each step there are a number of requirements to be completed which provide the SQE with all the necessary knowledge to truly understand the supplier GAP’s , whether it is an existing supplier to be improved or selection of a new supplier. These will include;

  • Detailed Process Mapping and review of where testing should be added to ensure supplier has maximum in process defect detection capability
  • PFMEA and definition of detailed process control plan to address all possible process risks
  • Gauge R&R of process test equipment   
  • Defining process measurement methods to select for appropriate points in process (% yield, ppm, DPPM, Ave no, defects per unit, etc
  • Setting up the most efficient and effective Early Life reliability stress test to prove supplier process reliability levels
  • Etc

All of the necessary requirements as above and techniques are covered in the 2 day training leading up to bringing all the measures into an ‘Holistic’ summary with a scoring approach to provide a TOTAL scored evaluation of the supplier in a totally different manner to traditional methodology. This is known as the ‘NPI Transition Matrix’ which can be altered for any process to provide an output score for excellent supplier benchmarking and acts as part of supplier continual improvement to reach higher score 

A scored NPI Matrix could look like the example below;

Let Reliability Solutions show you how companies have adopted the 6 step model approach to get quantifiable improvements that were never thought feasible.

Check out our agenda here:

Improving Supply Chain Quality with a Modern Effective Approach and ‘Managing by Measurement’

Why pay money buying expensive software to try to find a solution to your reliability challenges?

Engineers need much more than this, theory and fundamentals are important to understand your approach but planning the optimum balanced and affordable reliability improvement strategy requires a great deal more! 2019 is already proving an exciting year for Reliability Solutions training on implementing successful, low cost Reliability Improvement programmes for many clients in Asia and… Continue Reading

Reliability Solutions Seminars 2019 & Beyond

Reliability Solutions Seminars continue to reach many more engineers in a wide range of companies and 2019 will be no different. The latest agenda truly addresses the issues engineers face with predicting Reliability with less budget to do so and less time to complete. NONE of the models and solutions delivered by Reliability Solutions are… Continue Reading

2019 Agenda & Plans

2019 will be an exciting year for Energy 1 and Reliability Solutions as they roll out the new 2019 agenda packed with case studies and modelling solutions to solve all problems engineers face with performing reliability Testing and MINIMISING risk at new product introduction stage. New presentation modules on Statistical approaches and how to maximise… Continue Reading

Achieving High Reliability with small sample sizes – Is it really possible??

Do you often wonder why you can pass Reliability qualification tests with set sample sizes, but still cannot achieve the Reliability levels customers demand?? If you consider AQL tables where sample sizes for achieving nominated Quality levels are set around Accept and Reject defect numbers, the Quality levels such as 0.65% or 6500 ppm are… Continue Reading

Managing Process Quality to Drive World Class Customer Performance – 26-27 Oct

Hello Folks, We recently ran a very well received training programme on Quality Control in Shenzhen, China on Oct 26-27. The program is an entirely new education package to help companies drive World Class Quality in their manufacturing processes. In my role as Reliability consultant with many companies over the last 20 yrs, I have helped… Continue Reading

Managing Process Quality to drive World Class Customer Performance

You are normally seeing the marketing of our Reliability Training seminars held worldwide. Today we are announcing an entirely new education package to help companies drive World Class Quality in their manufacturing processes. Martin Shaw of Reliability Solutions has worked with multiple companies over the last 20 yrs as consultant and implemented many different methods… Continue Reading

Now In Partnership With Tangent Engineering

At Reliability Solutions, we are pleased to announce our new partnership with TANGENT Engineering. Tangent Design Engineering is a Calgary, Alberta based product design development and engineering services team. Tangent has a diverse multidisciplinary team of mechanical engineers, electrical engineers, simulation engineers, industrial designers, and firmware engineers. Tangent Design Engineering has been in business for… Continue Reading