Sandeep Singh

Keep a same formatting structure across all QMS documents! ❌I have made smaller mistakes like forgetting date of the record while designing format. ✅This lead me to the system which can help reduce common errors. 3 Points which will provide strong structure 1/ Header# a/ Name of the format b/ ID of the format c/ Revision details d/ Common title block - You can decide Department wise here, like for Quality department some of the data to be mentioned in all documents similarly for other departments. [Customise according to format requirement while using it] 2/ Footer# a/ Common Block of approval of document b/ Revision History Table c/ Department wise approval block like one mentioned in header 3/ Format Style a/ Font Type b/ Font Size c/ Format size like A4 or A3 as per requirement including Portrait or landscape formatting ☑️Make a structure and use it when changing or making a new format for consistency and error reducing. Follow Hetal Mehta for more on QMS and training

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Assessing FMEA Effectiveness: Key Indicators. FMEA (Failure Mode and Effects Analysis) is a proactive tool used to identify and mitigate potential failures within a process, product, or system. Here are a few points to consider when assessing the effectiveness of an FMEA:   📉 Reduction in Failure Rate 🛡️ Prevention of High-Risk Failures 📈 Improved Reliability and Quality 💰 Cost Reduction 🔄 Feedback from Stakeholders Do share below what do you consider as the key indicator for FMEA effectiveness    #quality #FMEA #Riskanalysis #Manufacturing 

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Possible important changes in IATF Rule 6th Edition--- *Max. reduction for a Corporate Scheme is now 15%. *Max. reduction for an upgrade from LOC or ISO 9001 to IATF is now 30%. *An Extended Manufacturing Site (EMS) must only be max. 10 miles/ 16 km away from the supported production site. *Mandatory times for the verification of NCs: 1-3 hrs for Majors and 0.5-1 hr for Minors. *Max. audit time per day 10 h = 8 h Audit Time + max. 2 h Additional Time. *Surveillance Audits = DD +/-3 months - if timeline is exceeded, there will be no suspension process but the certificate has to be withdrawn. *30 Days prior to the start of the audit the client needs to submit the audit preparation documents to the auditor. *If - due to confidentiality reasons a required document (e.g. Management Review) is not submitted, min. 2 hrs additional time has to be added to the audit. *15 Days (previously 20 days) after issuing a major NC the necessary documents have to be sent to the auditor (e.g. implemented Containment Action as well as Verification of Containment Effectiveness, Root Cause Analysis, implemented Correction and Systemic Corrective Action Plan). *For "100% resolved, but open" NCs, there is now only a „one-time Special Audit" which needs to be done min. 90 days before the next regular audit. *30 days prior to the „one-time Special Audit" the client has to submit evidences that the systemic corrective actions have been implemented and internally verified. If the "100% resolved, but open" NC cannot be closed in the "one-time special audit", the certificate has to be withdrawn. *If the systemic corrective actions for major NCs are not effectively implemented, the certificate has to be withdrawn. *There are only 2 reasons now to initiate the Decertification Process: a) Performance Complaint raised vs the certified client or b) NCs issued during RA, SA or SPA. *A Technical Review has to be conducted within 15 days after the Stage 1 Audit without technical review the Stage 2 Audit cannot be started. *Minimum 20 days need to be allocated between the end of the Stage 1 Audit and the beginning of the Stage 2 Audit. #iatf #auditor #aiag

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SPC typically stands for Statistical Process Control. It is a method used in quality management that employs statistical methods to monitor and control a process to ensure that it operates at its full potential. Here are some key points about SPC: 1. Purpose: The primary goal of SPC is to identify and reduce variability in manufacturing processes, leading to consistent and high-quality products. 2. Tools and Techniques: - Control Charts : These are the primary tools in SPC, used to plot data points over time and identify any signals or patterns that indicate a deviation from the process's normal behavior. - Process Capability Analysis: This involves assessing the ability of a process to produce output within specification limits. - Pareto Charts: These help identify the most significant factors in a dataset. - Cause and Effect Diagrams: Also known as fishbone diagrams, these help identify potential causes of defects or problems. 3. Implementation: SPC is implemented by collecting data from the process and using it to calculate control limits. When data points fall outside these limits, it signals that there may be a problem in the process that needs to be addressed. 4. Benefits: Proper implementation of SPC can lead to improved product quality, reduced waste, lower costs, and increased customer satisfaction. #Quality #System improvement #Hse

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Advanced Product Quality Planning (APQP) is a structured process used in manufacturing industries, including home appliances, to ensure that quality is built into products from the initial stages of design through production. As a mechanical quality engineer specializing in home appliances and sheet metal manufacturing with powder coating, APQP plays a crucial role in ensuring the quality and reliability of your products. In your field, APQP involves several key steps tailored to the specific requirements of home appliances manufacturing: ✨Product Design and Planning: This phase involves defining product requirements, functionality, and customer expectations. As a quality engineer, you collaborate closely with design and engineering teams to ensure that product designs meet quality standards and are manufacturable. For example, you may conduct design reviews to assess manufacturability and identify potential quality risks early in the design process. ✨Process Design and Development: In this phase, you focus on developing manufacturing processes that can consistently produce high-quality products. This includes selecting appropriate materials, manufacturing methods, and production equipment. For instance, you may work on optimizing sheet metal forming processes to minimize defects and ensure dimensional accuracy. Additionally, you collaborate with suppliers to ensure that raw materials and components meet quality requirements. ✨Product and Process Validation: This step involves validating product designs and manufacturing processes through prototyping, testing, and validation activities. For example, you may conduct performance tests on prototype home appliances to verify functionality and durability. In addition, you oversee process validation activities such as capability studies for sheet metal forming and powder coating processes to ensure that they meet quality standards and can consistently produce defect-free parts. ✨Production Launch and Feedback Assessment: Once the product and processes are validated, you oversee the production launch and monitor initial production runs to identify any issues or deviations from the planned process. For instance, you may conduct regular audits of the sheet metal fabrication and powder coating processes to ensure compliance with quality standards and identify opportunities for continuous improvement. ✨Continuous Improvement: APQP is not a one-time activity but rather a continuous process of improvement. As a quality engineer, you play a key role in driving continuous improvement initiatives aimed at enhancing product quality, reducing defects, and improving manufacturing efficiency. For example, you may lead cross-functional teams to implement corrective and preventive actions based on quality data analysis and feedback from production processes. #QualityEngineering #ManufacturingExcellence #HomeAppliancesQuality #SheetMetalManufacturing #PowderCoating #APQPProcess #ProductDesign #ProcessValidation

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OEE calculated in terms of basic six big losses, which is essential function of Availability, Performance rate, and quality rate of machine, production line or Factory whichever is the focus of OEE application. OEE (%) = Availability (%) *Performance rate (%) *Quality rate (%) (1) Where Availability (%) = Actual operating time (min) X 100 (2) Planned operating time (min) Performance rate (%) = (Net operating rate X Operating speed) X 100 (3) Quality rate = Total no. produced –No. Scrapped X100 Total no. produced The most important objective of OEE is not to get an optimum measure, but it indicates in which area improvement is needed

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Statistical Process Control (SPC) is one of the 5 Core Tools of Quality. SPC is a systemic, statistical method of collecting, monitoring and analyzing data about a process, checking for unexpected variations in the data and correcting any issues. It helps to determine whether the process is in or out of control. SPC helps reduce scrap, waste, defects, and rework, improve product quality, eliminate variation in processes, minimize costs and maintain compliance with regulatory and customer requirements. I’m happy to share that I’ve obtained a new certification: Implementing Statistical Process Control (SPC) from AIAG - Automotive Industry Action Group ! #qualityengineering #coretools #spc #aiag #productquality #statisticalanalysis #processimprovement

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Poka-Yoke: An Essential Tool for Error Prevention in Manufacturing Poka-Yoke, a Japanese term meaning "mistake-proofing" or "error-proofing," The concept is : implement mechanisms that either prevent mistakes from occurring or immediately correct them if they do happen. History📑of Poka-Yoke The term Poka-Yoke was developed by Shigeo Shingo, an industrial engineer at Toyota, in the 1960s. Initially, the concept was known as "Baka-Yoke," which means "fool-proofing," but it was later changed to Poka-Yoke. Shingo's realized that many defects were caused by simple human errors, such as missing parts or incorrect assembly. By designing processes and tools that made it impossible to make these errors, he significantly improved the quality and reliability of the products. Poka-Yoke devices and systems can be categorized into three types: contact methods, fixed-value methods, and motion-step methods. 1️⃣ Contact Methods These methods use physical attributes to detect errors. For example, a machine might be designed with a specific shape or size that only allows the correct part to fit. Example ▶ A jig with a specific shape that only allows correctly shaped components to be inserted. 2️⃣ Fixed-Value Methods These methods monitor fixed values, such as the number of parts or operations, to ensure accuracy. Example ▶ A counter that tracks the number of screws used in an assembly. If the correct number is not reached, the process cannot proceed. 3️⃣ Motion-Step Methods These methods ensure that the correct sequence of operations is followed. If a step is skipped or performed out of order, the process stops. Example ▶ An assembly line that requires specific actions in a sequence, with sensors that detect if a step is missed. Levels of Poka-Yoke 1️⃣ Error Prevention The highest level of Poka-Yoke, where mechanisms are in place to make it impossible for errors to occur. Example ▶ A connector that only fits in one orientation, preventing incorrect assembly. 2️⃣ Error Detection This level focuses on detecting errors as they occur and immediately signaling the problem so it can be corrected before moving on to the next step. Example ▶ A light sensor that detects if a part is missing and stops the production line. 3️⃣ Error Mitigation The lowest level, where the system allows errors to occur but provides means to easily identify and correct them later. Example ▶ A checklist used by workers to verify steps after the process is completed.

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Understanding Common cause variation and Special cause variation in SPC: 🔔 In statistical process control (SPC), Common cause variation refers to the inherent, expected fluctuations in a process due to factors like machine wear🧰, environmental conditions⛈️, or operator👷 skill levels. These variations are consistent, predictable, and fall within the normal range 📉 of operation. 🔔 Special cause variation arises from specific, identifiable factors that are not part of the usual process. Examples include machine and tool🛠️ malfunctions, material contamination🔬 and operator errors, leading to sudden and significant deviations from the expected output. Recognizing and distinguishing between these types of variation is essential for maintaining process stability and identifying opportunities for improvement📈 in quality control and production efficiency. Add your views for special cause and common cause🔊💐🧭💡🚀🏆🌄 #spc #controlcharts #histogram #specialcause #commoncause #variation #processcontrol #deviation #qualitycontrol #improvement

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COST OF QUALITY (COQ)?? Cost of quality (COQ) is defined as a methodology that allows an organization to determine the extent to which its resources are used for activities that prevent poor quality, that appraise the quality of the organization’s products or services, and that result from internal and external failures. Having such information allows an organization to determine the potential savings to be gained by implementing process improvements. 👉WHAT IS COST OF POOR QUALITY (COPQ)? Cost of poor quality (COPQ) is defined as the costs associated with providing poor quality products or services. There are three categories: Appraisal costs are costs incurred to determine the degree of conformance to quality requirements. Internal failure costs are costs associated with defects found before the customer receives the product or service. External failure costs are costs associated with defects found after the customer receives the product or service. Quality-related activities that incur costs may be divided into prevention costs, appraisal costs, and internal and external failure costs. 👉Appraisal costs Appraisal costs are associated with measuring and monitoring activities related to quality. These costs are associated with the suppliers’ and customers’ evaluation of purchased materials, processes, products, and services to ensure that they conform to specifications. They could include: 👉Verification: Checking of incoming material, process setup, and products against agreed specifications Quality audits: Confirmation that the quality system is functioning correctly Supplier rating: Assessment and approval of suppliers of products and services 👉Internal failure costs Internal failure costs are incurred to remedy defects discovered before the product or service is delivered to the customer. These costs occur when the results of work fail to reach design quality standards and are detected before they are transferred to the customer. They could include: 👉Waste: Performance of unnecessary work or holding of stock as a result of errors, poor organization, or communication Scrap: Defective product or material that cannot be repaired, used, or sold Rework or rectification: Correction of defective material or errors 👉Failure analysis: Activity required to establish the causes of internal product or service failure External failure costs External failure costs are incurred to remedy defects discovered by customers. These costs occur when products or services that fail to reach design quality standards are not detected until after transfer to the customer. They could include: 👉Repairs and servicing: Of both returned products and those in the field Warranty claims: Failed products that are replaced or services that are re-performed under a guarantee Complaints: All work and costs associated with handling and servicing customers’ complaints Returns: Handling and investigation of rejected or recalled products, including transport costs.

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Cost of Quality. It is truth that the time spent for quality is always good.. But some times we focus on fixing things and repeating the same mistake. We need to understand what is the cost spent on quality. In the below picture, few of the categories of cost of good quality and bad quality. #cost #quality #coq #good #bad #Planning #defect

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🌟 𝐄𝐧𝐡𝐚𝐧𝐜𝐢𝐧𝐠 𝐑𝐞𝐥𝐢𝐚𝐛𝐢𝐥𝐢𝐭𝐲 𝐰𝐢𝐭𝐡 𝐅𝐚𝐢𝐥𝐮𝐫𝐞 𝐌𝐨𝐝𝐞 𝐚𝐧𝐝 𝐄𝐟𝐟𝐞𝐜𝐭𝐬 𝐀𝐧𝐚𝐥𝐲𝐬𝐢𝐬 (𝐅𝐌𝐄𝐀) 🌟 FMEA- the second core tool of Quality... In the quest for excellence and reliability, identifying potential failures before they occur is crucial. Failure Mode and Effects Analysis (FMEA) is a systematic approach designed to foresee potential issues and mitigate risks in products and processes. 🌟 𝐖𝐡𝐚𝐭 𝐢𝐬 𝐅𝐌𝐄𝐀? FMEA is a proactive tool used to identify and evaluate potential failure modes of a product or process and their effects. By systematically analyzing these potential failures, teams can prioritize risks and implement corrective actions to prevent issues from arising. 🌟 𝐊𝐞𝐲 𝐒𝐭𝐞𝐩𝐬 𝐢𝐧 𝐅𝐌𝐄𝐀: 1. Identify Potential Failure Modes: Determine all the ways in which a product or process can fail. 2. Assess the Effects of Failures: Analyze the impact of each failure mode on the product, process, or customer. 3. Determine Causes: Identify the root causes of each failure mode. 4. Assign Risk Priority Numbers (RPN): Evaluate the severity, occurrence, and detectability of each failure mode and calculate the RPN to prioritize risks. 5. Develop and Implement Actions: Plan and execute actions to eliminate or reduce high-priority risks. 6. Review and Update FMEA: Continuously monitor and update the FMEA as new information and feedback become available. 🌟 𝐖𝐡𝐲 𝐅𝐌𝐄𝐀 𝐌𝐚𝐭𝐭𝐞𝐫𝐬: - Risk Mitigation: Proactively identifies and addresses potential failures, reducing the likelihood of costly errors and rework. - Improved Reliability: Enhances the reliability and robustness of products and processes by addressing weaknesses before they result in failures. - Customer Satisfaction: Ensures that products meet customer expectations by preventing issues that could impact performance or safety. - Continuous Improvement: Fosters a culture of continuous improvement by systematically identifying and addressing potential issues. 🌟 𝐈𝐦𝐩𝐥𝐞𝐦𝐞𝐧𝐭𝐢𝐧𝐠 𝐅𝐌𝐄𝐀 𝐒𝐮𝐜𝐜𝐞𝐬𝐬𝐟𝐮𝐥𝐥𝐲: - Cross-Functional Teams: Involve team members from different functions (engineering, quality, manufacturing) to ensure a comprehensive analysis. - Thorough Documentation: Document all findings and actions meticulously to ensure traceability and accountability. - Regular Reviews: Schedule regular reviews to update the FMEA based on new data, feedback, and changes in the product or process. FMEA is a powerful tool that helps organizations anticipate and mitigate risks, leading to more reliable products and processes. By embracing FMEA, we can drive quality, enhance customer satisfaction, and achieve operational excellence! #QualityManagement #FMEA #RiskManagement #Reliability #ContinuousImprovement #QualityAssurance --- 𝐕𝐚𝐢𝐛𝐡𝐚𝐯 𝐆𝐡𝐚𝐫𝐚𝐭

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API 580 Risk-Based Inspection: A Comprehensive Guide API 580 Risk-Based Inspection (RBI) standard provides a framework for prioritizing and managing inspection activities based on the risk of failure and potential consequences. This approach helps organizations optimize their inspection resources, reduce costs, and improve overall asset integrity. In this article, we will delve into the details of API 580 RBI, its benefits, and how it can be implemented effectively. What is API 580 Risk-Based Inspection? API 580 RBI is a risk assessment and management approach that identifies and prioritizes potential failure modes, assessing their likelihood and consequences. This methodology considers factors such as equipment criticality, process conditions, material degradation, and historical failure data to determine the inspection frequency and scope. Key Components of API 580 RBI 1. Risk Assessment: Identifies potential failure modes, likelihood, and consequences. 2. Risk Ranking: Prioritizes equipment based on risk scores. 3. Inspection Planning: Determines the scope, frequency, and type of inspections. 4. Data Management: Collects and analyzes inspection data to refine the RBI process. Benefits of API 580 Risk-Based Inspection 1. Optimized Inspection Resources: Focuses resources on high-risk equipment. 2. Reduced Costs: Decreases unnecessary inspections and maintenance. 3. Improved Asset Integrity: Enhances reliability and availability. 4. Enhanced Safety: Identifies and mitigates potential safety risks. Implementation Steps 1. Data Collection: Gather equipment information, process conditions, and failure history. 2. Risk Assessment: Conduct a thorough risk assessment using API 580 guidelines. 3. Risk Ranking: Prioritize equipment based on risk scores. 4. Inspection Planning: Develop an inspection plan based on risk ranking. 5. Continuous Improvement: Refine the RBI process through data analysis and feedback. Conclusion API 580 Risk-Based Inspection offers a proactive approach to asset management, enabling organizations to prioritize inspections based on risk and optimize resources. By implementing API 580 RBI, companies can improve asset integrity, reduce costs, and enhance safety. Remember, effective implementation requires careful data collection, risk assessment, and continuous improvement. Embrace API 580 RBI to transform your inspection strategy and ensure the reliability and efficiency of your assets.

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OEE (Overall Equipment Effectiveness) OEE (Overall Equipment Effectiveness) is a key performance indicator used in manufacturing and production environments to measure the efficiency and productivity equipment and processes. The benefits of implementing OEE include: Optimizing Equipment Utilization: OEE helps optimize the use of manufacturing equipment by identifying bottlenecks and inefficiencies. This leads to better scheduling of production activities and maximize the return on investment in equipment. Reducing Downtime: OEE highlights downtime events and their causes, allowing teams to implement strategies to reduce or eliminate unplanned downtime. This results in increased equipment availability and productivity. Improving Quality: OEE considers the quality of output alongside performance and availability metrics. By focusing on improving OEE,organizations can enhance product quality and reduce defects. Enhancing Overall Productivity: OEE provides a holistic measure of equipment performance,helping organizations track progress over time and performance improvement goals. By consistently Improving OEE, organizations can achieve higher overall productivity. Enabling Data-Driven Decision Making: OEE generates actionable data that facilitates informed decision-making. This includes decisions related to maintenance schedules, process optimizations, and resource allocation. Visibility and Transparency: OEE provides a comprehensive view of equipment performance, highlighting areas of inefficiency and downtime. This visibility enables teams to identify root causes of problems and implement targeted improvements. Identifying Improvement Opportunities: By analyzing OEE metrics, organizations can pinpoint specific areas for improvement such as reducing downtime,improving cycle times, or enhancing quality. This data-driven approach helps prioritize improvement efforts for maximum impact. Cultural Shift towards Continuous Improvement: Implementing OEE fosters a culture of continuous improvement within the organization. Teams are encouraged to actively seek ways to optimize performance,leading to sustained productivity gains. Standardizing Performance Metrics: OEE provides a standardized way to measure equipment performance across different processes and facilities within an organization. This consistency enables benchmarking and comparison, driving further improvements. Resource Optimization: OEE helps optimize resource utilization, including labor,materials, and energy. By identifying inefficiencies in equipment performance, organizations can streamline resource allocation and reduce waste. Enhanced Equipment Reliability: Improving OEE often leads to greater equipment reliability and longevity. Addressing root causes of equipment inefficiencies reduces wear and tear, ultimately extending the lifespan of machinery. #lean #manufacturing #production #OEE #Composite #aerospace #UAV #Automobile #Engineering #improvement #5S #Kaizen

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What's 1 thing keeps people from following QMS & what to do for it? ➡️ The hard thing about Management systems# ❌ More often MS are designed and documented keeping in mind the standards and words used by it. ❌ When essence of a management system is to implement the given standard but following terminology and only stating requirements as a reason for system keeps people from understanding it. ❌ People from all department do not know standard terminology and the reason behind a requirement, and this disconnect people from system as they don't know why to follow and don't clearly understand what to follow! ➡️ The Most Promising Solution# ✅ It lies in making system easy to understand and follow. ✅ Address standard's requirement but use the words that people from your organization understand. ✅ Customise as much as the system to easily implement at the level of user of the system rather than making it at the level of maker of standards and systems. _______________ ❄Follow Hetal M. for more on QMS ♻️ Repost, 👍Like or share what would you add❔ ________________ What did you find most hard about following QMS?

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What is PPAP | PPAP Documents | Levels of Submission | Production Part Approval Process | https://lnkd.in/ga2fNKDk #qualityhubindia #aryanviswakarma #PPAP #ProductionPartApprovalProcess #QualityControl #AutomotiveIndustry #ManufacturingStandards #PPAPRequirements #SupplierQuality #APQP #PPAPDocumentation #PPAPSubmission #QualityAssurance #ISOTS16949

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How to Adopt a Zero Defects Approach A zero defects approach is a quality management philosophy that aims to eliminate errors and defects in all production or service delivery stages. Below are some steps that can help you adopt a zero defects approach: 1.Create a culture of quality: Emphasize the importance of quality throughout the organization. Train employees to focus on quality in every aspect of their work and encourage them to take pride in delivering defect-free products or services. 2.Establish clear quality standards: Define quality standards for all processes and products, including metrics to measure and monitor quality. Ensure that everyone in the organization understands and follows these standards. 3.Identify potential defects: Conduct a thorough analysis of all processes and products to identify potential sources of defects. This can include analyzing customer feedback, conducting quality audits, and reviewing production processes. 4.Develop preventative measures: Once potential defects are identified, develop preventive measures to eliminate or reduce the risk of defects occurring. This can include implementing quality control measures, improving training programs, and using more reliable production processes. 5.Monitor and measure quality: Continuously monitor and measure quality to ensure that processes and products meet established quality standards. Use data and feedback to identify areas for improvement and adjust processes as needed. 6.Encourage continuous improvement: Continuously look for ways to improve processes and products to achieve even higher levels of quality. Encourage employees to provide feedback and ideas for improvement.

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What is quality Control? Quality control for manufacturing company title itself suggest that Manufacturing process is the key and Quality control is based on what can go wrong in the process. What are the variables which are absolutely essential, what can be chosen from the available choices but once chosen becomes essential and then cannot be varied and last is what has tolerance which is more forgiving or can be altered later.  Considering above is process well documented and explained to the operators, supervisors, is process qualified for at least one level higher assembly if not for the final product.  Now we need to put checks based on above for 100% inspection by operator personally or using IoT. If IoT 's are used or automation in screening, 70 % will pass through easily and random inspection can be done in this 70% but balance 30% shall be 100% inspected till you reach CpK of 1.6 or better. Once consistency in inputs and out put is achieved we can bring down inspection in stages to 13%. One will see IoT screening will jump and variations if any will have a trend, which is easy to correct and at this we shall say QA is effective 

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As a Quality & Qms Domain Industry Professional what my personal Experience Most of the Time Interviewer Ask Basic fundamentals to Terminology Related to Domain which is Show Our Depth of knowledge and Level Interviewer can Easily judge by Asking These Fundamentals and Recent Development in Field

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