Traceability is important for us and we use our MRP system to link material, operator, machine and quality documents to our manufacturing orders. In the unlikely event that a deviation should arise, we are able to later analyze the process performance.
When we have the opportunity we prefer to purchase a whole batch size of material from the mill. We always use material from the same batch for a single production order. This make it possible for us that the components will be produced with the same material properties both in our own production and in the subsequent surface treatment.
Our control plans define the quality process which must be performed for each item. They enable us, in a safe way, to produce the component with the same quality every time. We thus also have the possibility with the control plans to incorporate experience from our final inspection and customer feedback.
Each time an operator sets a machine he performs a self-monitoring in order to verify that the produced article conforms to the specifications. With this stage complete he asks the quality manager to perform the first piece control check. After getting approved, it is time to start production and begin with the control measurements in accordance with the control plan. When production of an article runs during multiple shifts a new complete control measuring is done before a new operator takes over. In addition, we always do a final complete check of the last component produced to ensure that no issues have occurred towards the end the production process.
The signed inspection plan is archived so that we can easily go back and review it should any deviations later occur. When we use subcontractors, for example for surface treatment, we always bring the articles back to HAMEK for final inspection and shipment packing.
In case of any deviations, we use an 8D-based exception handling. We ask the five critical “why-questions”, confirm the deviation within 24 hours and make every effort to sort out the root cause within a week.