PRESS RELEASE
The Right Approach Consulting
April 9th, 2018
Waukesha, WI

Alloy Products Corp. Receives ISO 9001: 2015 Certification
I am proud to announce that client Alloy Products Corp. has received certification to ISO 9001: 2015 from registrar TUV. The company had a solid quality foundation going in from many years of certification to prior revisions of the standard, and through the transition to ISO 2015, A-P-C realized significant process improvement and simplification of the QMS. President Betsy Bear-Hoff, ISO Administrator Lynda Vick and the entire A-P-C staff were an absolute delight to work with and got the job done without a hitch.

About Alloy Products Corp
A leader in the fabrication of stainless steel and other alloys since 1929, Alloy Products Corp. consistently meets or exceeds the most rigorous industry standards. APC manufacturers portable pressure vessels & fixed pressure vessels manufactured to ASME and UN specifications used in a variety of sanitary, industrial and general purpose applications. The pressure vessels are constructed of stainless steel and other modern alloys. These pressure vessels are designed for dispensing, mixing or storing hazardous, corrosive, high purity or flammable products to 13.8 bar (200 psi). Few manufacturing facilities can match their superior craftsmanship and quality assurance in designing and manufacturing a wide variety of stainless steel pressure vessels and containers.

For more information, they can be reached at 800.236.6603, or through their website https://www.alloyproductscorp.com

“We strive to decide our own fate. We act with self-reliance, trusting in our own abilities. We accept responsibility for our conduct and for maintaining and improving the skills that enable us to produce added value.” –Excerpt from Toyota Motor Corporation’s internal document titled “Toyota Way”.

Wrong Headed Thinking

The opening quote captures the values and ideals of Taiichi Ohno, one of the inventors of the Toyota Way that were tasked with transforming Toyota into the world-class manufacturing enterprise that it is today. Some of my columns may sound like a broken record to my readers regarding best practices / lean as a “be-all, end all” to every problem a company can have. It may surprise you that I strongly disagree with that; as lean certainly has limitations and does not play particularly well in high-mix, low volume (HMLV) operations like PCB manufacturing. That being said, what I do believe is that there are very few problems that cannot be helped with a thoughtful, selective application of best practice tools appropriate to the situation.

Unfortunately, one of the first reactions to a process problem with many companies, especially in a very complicated operation like PCB manufacturing, is to throw more inspectors at it. This knee-jerk reaction has a triple impact on profits:

  1. Inspection by definition is a non value-add reactive processbest_practice
  2. It doesn’t address the root cause of the issue and assures it will resurface at some point
  3. Inspection is not effective

Identifying and fixing problems instead of foolishly trying to “inspect in quality” by sorting will have a greater impact on profit than raising prices your product, hammering your suppliers for lower costs or most any other traditional profit enhancement initiatives an organization can implement.

Give me a call to help you stop throwing profits out the door!

920-841-3478

Steve@TheRightApproachConsulting.com

 

 

I think you might be interested in reading my latest column “The Rebirth of Made in America”, which can be found at: http://iconnect007.uberflip.com/i/950499-pcb-mar2018/76

I am excited to inform you that my interview, “Defining Customer-Supplier Relationships and Customer Satisfaction,” has now been published in SMT007 Magazine. I invite you to read the full story here,
http://iconnect007.uberflip.com/i/935136-smt-feb2018/32

 

Register now for my IPC/APEX PCB Executive Forum to learn how to implement W.O.R.C., a new lead time reduction strategy for high-mix, low-volume manufacturing operations. Join me Monday, February 26 at 2:00 pm by registering at: http://www.ipcapexexpo.org/html/register/default.htm

PCB Executive Forum WORC 2018

Highlights

Lean, theory of constraints (ToC), quick response manufacturing (QRM), cross-training, and SPC are powerful, tried and true methodologies for process improvement. However, these tools are rooted in high-volume manufacturing environments and don’t always play nice in a high-mix, low-volume (HMLV) operation. The new W.O.R.C. cycle reduction strategy (Workflow Optimized for Rapid proCessing) was specifically developed to overcome these shortcomings while capitalizing on their strengths.

What You Will Learn

  • Limitations of the Current Toolset
  • Introducing W.O.R.C.
  • Physical, Virtual & Hybrid W.O.R.C. Cells
  • W.O.R.C. Cell Cross Training
  • Myth-Busting Traditional Thinking
  • W.O.R.C. Cell Thinking
  • Strategically Planning For Spare Capacity
  • Office W.O.R.C. Case Study
  • Manufacturing W.O.R.C. Case Study

Who Would Benefit

Manufacturing, production and operations professionals in high-mix, low-volume manufacturing organizations that want to reduce cycle time and improve on time delivery.

About the Instructor

Steve Williams is a 40-year veteran in the electronics industry, having gained prominence and recognition as an authority on manufacturing, quality and management. The former Sourcing Manager for global EMS provider Plexus Corp., he is currently the President of The Right Approach Consulting. Steve has authored numerous books, including Lean, Quality and Leadership, has published more than 150 business articles & white papers, and is a columnist for The PCB Magazine at i-Connect007.

 

 

PRESS RELEASE

The Right Approach Consulting

February 13, 2018

West Bend, WI

Moraine Plastics Receives ISO 9001: 2015 Certification

I am proud to announce that client Moraine Plastics has received certification to ISO 9001: 2015 from registrar Intertek. The company had a strong quality foundation going in from many years of certification to prior revisions of the standard, and the transition was fairly straight forward. Quality Manager Jeff Weinert and the Moraine Plastics team were a delight to work with, and got the job done without a hitch in an expedited timeframe.

About Moraine Plastics

Moraine Plastics is a manufacturer of High Volume Custom Plastic Injection Molded parts and products for customers around the world.  They are one of 3 manufacturing companies in the PM Plastics family, along with PM Plastics Co. and Nitschke Mold & Manufacturing. The group has been a family-owned and operated full-service plastic injection molding U.S. contract manufacturer since 1946. Moraine Plastics Logo cmykThey are a solid partner to businesses and industries who manufacture their products in the United States. With over 70 years of experience in manufacturing, they provide a wide range of services from concept to the consumers hands through quality control, engineering and project management.

For more information, they can be reached at (262) 335-0601 or through their website http://www.pmplastic.com

 

Operational excellence takes work; more specifically, it takes relentless execution. There should be no lack of available continuous improvement projects in the average PCB or other custom component manufacturer. Developing a strategy for identifying the potential projects should be the first step in the process. Using defect data and Pareto analysis you can easily see where the largest dollar return can be gained in each functional manufacturing unit. Customer complaints, quoting accuracy, and customer (external and internal) surveys are good sources for identifying continuous improvement projects within support functions. Focusing on improving the top 3 issues within any one functional unit will achieve much higher return than trying to reduce the bottom 80% if the issues (the old reliable 80/20 rule).

Lombardiwinning

Developing solutions that result in improvement can be expedited by utilizing tools such as Failure Mode Effects Analysis (FMEA), Process Control Plans, SPC reports & Process Capability (CPK) data, and Gauge R & R Studies. Advanced problem-solving techniques such as Group Brainstorming, Ishikawa (fishbone) Cause & Effect Diagrams, and Design of Experiments (DOE) are very effective in facilitating root cause analysis.

Give me a call to start operational excellence in your company!

920-841-3478

 Steve@TheRightApproachConsulting.com

Formal improvement teams are arguably the most effective continuous improvement vehicle available to an organization. When resources are scarce, many companies are using their TRB (technical review board) as a CI team. Providing group dynamics and team building training to teams increase their effectiveness exponentially. Companies have come up with some very creative names for their teams, and creativity does help sell the concept to employees (PIT Crews, OpX, Tiger Teams, etc.).

The modern continuous improvement team got its roots back in the 1960’s when my former professor Dr. Ishikawa invented “quality circles”. Teams generally are permanent entities assigned to specific processes, with a cross-functional membership empowered to make organizational decisions. It may also be advisable to rotate some members to provide fresh perspective and prevent team burnout. No matter how you approach it, the old adage has never been more true: two heads are always better than one.

2heads

Give me a call to start operational excellence in your company!

920-841-3478

Steve@TheRightApproachConsulting.com

The underlying philosophy, which ensures the success and growth of an organization, is that every facet of the operation must continuously improve. This means that instead of having one specific objective that once met signals the end of progressive effort, employees at every level of responsibility must always strive to perform better next month than last month. Such a never-ending plan defines excellence as continuous improvement. This philosophy must permeate the entire organization, not just manufacturing. Tremendous benefits can be achieved in the areas of customer service, sales and marketing, quality, & engineering, but are often overlooked in a continuous improvement program.

Right-State-Of-Mind

Give me a call to start operational excellence in your company!

 920-841-3478

Steve@TheRightApproachConsulting.com

 

Continuous improvement is a journey, and as with most things worthwhile, needs to be an integral part of an organization’s everyday life. It can only come from people, motivated and committed, learning what they can learn, solving problems that they can solve, and implementing solutions that they develop.

crisis_managementThe venerable quality guru W. Edwards Deming defined continuous improvement simply as “improvement initiatives that increase successes and reduce failures.” Sounds simple, doesn’t’ it? In concept it is simple, it is the execution that requires perseverance. The need for continuous improvement is present in every industry, but mandatory in technology industries with complex processes. Continuous improvement cannot be defined as putting together an ad-hoc group to “put out a fire”. Crisis management is not continuous improvement; crisis prevention is.

Give me a call to start operational excellence in your company!

920-841-3478

Steve@TheRightApproachConsulting.com