Manufacturing Best Practices

Preface.

Acknowledgments.

Chapter 1: Understanding Quality and Quality Requirements.

The End Result.

Quality.

Quality Control.

Quality Assurance.

The Quality System.

Quality Requirements and Specification Review.

Quality Requirements.

Final Thoughts.

Chapter 2: Testing.

Testing: What Is It?

Testing: Location, Technicians, and Training.

Procedures.

Final Thoughts.

Chapter 3: Inspection and Data Handling.

Inspection.

Plans and Procedures.

Data, Data, Everywhere!

Final Thoughts.

Chapter 4: Calibration.

Gauge Identification.

Calibration Standards.

Calibration Recall and Data Management System.

Moving beyond the Simple Recall System.

Out-of-tolerance Conditions.

Final Thoughts.

Chapter 5: Corrective, Preventative Action and Error Proofing.

When Is Corrective Action Required?

Requirements for a Corrective Action System.

Investigating and Resolving a Corrective Action Issue.

Corrective Action Resolution.

Error Proofing.

Preventative Action.

Final Thoughts.

Chapter 6: Document Control: Ensuring Vital Information Is Available to Those Who Need It.

Why Go to All This Effort?

Paper-based Systems.

Revision Control.

Document Distribution.

Uncontrolled Copies.

Electronically-based Systems.

Guidelines and Audits.

Final Thoughts.

Chapter 7: Process Control.

How Do I Do It?

Identifying Key Process Variables.

The Control Plan.

Equipment Set-up/Documentation and Verification.

Process Capability.

Monitoring.

Final Thoughts.

Chapter 8: Process Changes.

Request Submission.

External Communication of Changes.

Final Thoughts.

Chapter 9: Raw Materials, Services, and Suppliers.

Sourcing: Raw Materials.

Sourcing: Services.

After Sourcing: The Start of a New Relationship.

Final Thoughts.

Chapter 10: Customers.

The Start of a Beautiful Relationship.

Accessibility.

Contacts.

Availability.

Responsiveness.

Follow-up.

Customer Care.

Customer Satisfaction.

Customer Recruitment and Retention.

Final Thoughts.

Chapter 11: Physical Facilities.

Maintenance.

The Work Area.

Final Thoughts.

Chapter 12: People.

Education.

Training.

Mentoring.

Empowerment.

Employee Benefits.

Final Thoughts.

Conclusion.

Appendix: Quality Requirements Checklist.

About the Author.

Index.

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.