How to start your solutions programme
Reliability Solutions’ Martin Shaw will perform a detailed 2-day gap analysis of all key areas that could affect internal failure levels and customer fails. Following this, a comprehensive executive report will be produced detailing all areas for improvement and a proposed programme schedule to address these. An executive report produced by Martin would typically cover the following areas :
- Methods used for DFM assessments and how the reports are used
- How Design Quality levels are Measured and Controlled
- How Failure Prevention using Design FMEA (DFMEA) is applied
- Process Control methods applied and if they are suitable
- Quality / Reliability Test Reporting , is it sufficient to control outgoing Reliability?
- Reliability Test Methods employed, are they sufficient?
- Reliability Prediction tools used and how appropriate they are for the customers product line
- The link between process Yield and Early Life Failure Escape Levels
The report will define expected overall levels of process and reliability improvement attributable to Martin’s improvement programme, in addition to the timeframe required to effect improvements and cost reductions. This allows decision makers to identify a very clear ROI.
This stage plans a detailed continuous improvement programme containing individual improvement projects along with their associated KPIs (reliability level improvements, % design maturity and MTTF levels etc.). Carefully chosen KPIs are fundamental as they shape project teams’ activities and underpin support successful project completion.As part of the continual improvement programme, 6 month company / corporate objectives are identified, as are cost savings to be realised by improving reliability and reducing manufacturing process and field failure levels.
Martin will establish a formal review programme where progress against each KPI will be evaluated and corrective action, if necessary, will collectively be taken.