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The American Quality Associates (AQA) team has the product knowledge, technical skill and experience to help you improve your business.
Our experts can address your business needs on a regional and industry-specific level. We work closely with you to determine your needs, then collaborate with your team to define and map your processes. This joint effort delivers a world-class solution that makes a bottom-line difference.
Our services include:
On Site Quality Seminars and Training - Example Seminar Offerring
This seminar on how to improve product quality teaches proven tools for maximizing quality, minimizing scrap and rework, and increasing customer satisfaction with your products. It can be tailored to your company's specific needs and audience. Typical attendees include managers, engineering and technical support personnel, QC inspectors, R&D, and line personnel. Total course length is two days with hands-on exercises and all course materials.
§ Current State of the Business
§ Why Quality, Why Now?
§ Introduction to Past and Current Methods of Quality Control
1. Mil Std. Inspection Sampling Plans
2. Traditional Statistical Quality Control (SQC)
3. Traditional Statistical Process Control (SPC)
4. Multivariate SQC/SPC
Ÿ Importance of Evaluating your Measurement Process
5. Measurement Systems Analysis (MSA)
6. Sources of Variation Analysis
7. Nested Designs
Ÿ Variation Reduction and Product Quality
8. Taguchi's Loss Function
9. Target Based Quality Monitoring
10. Scoring Product and Service Quality
Ÿ Six Sigma Approaches to Quality Improvement
11. Structure & Benefits of Six Sigma
12. Applications/Examples
Ÿ Quality by Design
13. Basic Concepts of Experimental Design
14. Factorial and Variance Component Designs
15. Screening Designs for many Variables
Ÿ Collecting Customer Satisfaction Information
16. Approaches to Customer Research
17. Survey Design & Analysis
On Site Quality Consulting
We will consult on site to address ongoing and/or high impact quality problems to improve product consistency and cycle time, reduce waste, and minimize customer complaints. Some example Six Sigma quality improvement projects with savings of up to $3.5 million per annum are listed below:
Automotive Seat Systems Six Sigma Application
• Background/Opportunity
- 45,000+ Foam Seats per Day @ $ 10 per Seat
- 4.5% Scrap rate due to voids, ILD, dropped panels/wires, etc.
• Challenge
- Reduce foam seat scrap rate by at least 3.0%
• Measure/Analyze
- Joint Hourly/Salary Team established to reduce scrap rate
- Control Charts on line (KPOVs, KPIVs), Cpks, MSA
- Failure modes identified, DOE’s conducted on line
• Improve/Control
- Mold design modified (venting), cleaning practices revised on line, SPC implemented on KPIVs, operator training, etc..
• Sustain/Results
- Scrap rate reduced to < 0.7 %, savings of > $ 3.5 MM/Year
Military Aircraft Six Sigma Application
• Background/Opportunity
- D-MOD schedule changes resulted in missing 35% of customer shipments on CH-47 helicopters
• Challenge
- Reduce missed shipments to less than 5%
• Measure/Analyze
- Brainstorm/C&E/Pareto causes of schedule changes
- Confirmed missing/hoarded tooling as the key cause
• Improve/Control
- Improved Tooling requisition/control process
- Purchased additional tools to meet department needs
- Control charted schedule changes/total build time
• Sustain/Results
- 40+% productivity gain in D-MOD area, schedule changes reduced 70+ %.
Specialty Chemicals Six Sigma Application
• Background/Opportunity
- QC testing costs > $ 13 MM per year on a global basis
- Six Sigma teams formed
• Challenge
- Reduce global QC testing costs by at least 25%
- Improve test method capability from Cp of 1.2 to >= 2.0
• Measure/Analyze
- Regional QC resources survey conducted, MSA of key QC methods determined, Gage R&Rs, Round Robins
• Improve/Control
- Nested designs to identify key variance components, SQC of lab standards, Skip Lot & Optimized testing protocols established
- Performance goals established/monitored
• Sustain/Results
- Cp of test methods >= 3.0, $ 3.6 MM savings per year in QC costs on a global basis
Pharmaceutical Six Sigma Application
• Background/Opportunity
- Variability in extended release tablet dissolution at key 4 hour dissolution time point, Cpk of < 1.0
• Challenge
- Understand and control the sources of variation in dissolution to achieve a Cpk > 1.3
• Measure/Analyze
- Historical data analyzed via Multi-vari methods
- DoE conducted based on KPIVs identified from historical data analysis
• Improve/Control
- Operating ranges of KPIVs defined to optimize dissolution profiles
• Sustain/Results
- Cpk >1.3 achieved and process control established across all coating units
Employee Training (on-site)
Custom tailored to your needs
1-on-1 sessions
Classroom instruction for groups of up to 20
Call us at 609-417-1707 to see what we can do for you !
Development
If your business needs custom solutions, you've come to the right place. American Quality Associates's (AQA) expert development team is experienced in all phases of quality systems development and implementation. We listen to your needs and transform your wishes into a finished product quality system that performs to your needs. We also provide training so you and your staff learn how to get the most from your custom solution.
Staffing
When you're seeking short-term help for an urgent project or a business crunch, American Quality Associates (AQA) can provide the experienced employees you need. We provide temporary staffing at all skill levels-from entry-level to senior management-and in a range of industries. Let our reliable, experienced temporary employees relieve your worries.
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