Senior management is in charge of the total quality process control (TQPC) system. They provide the direction and assets that drive the quality program. The communication of recognizable benefi ts is key to the program. Management must ensure all personnel adopt the program ideals and follow its procedures and values.

The plan for establishing a TQPC program begins with understanding the business and manufacturing responsibilities. Personnel duties are determined, and a progression of steps are followed to ensure the correct information is available and used by all involved departments. How well information fl ows to the responsible personnel in an organization is a statement of the quality health of the company. All companies should have a quality manual that outlines the responsibilities and requirements to be performed and documented in the business and manufacturing process. Procedures are then developed with ISO 9001:2000, and the following six procedures are required:
1. Control of documents
2. Control of records
3. Planning, conducting, and reporting internal audits
4. Control of nonconforming product
5. Corrective action
6. Preventative action

Two additional procedures that may be considered to ensure additional quality operations may include the following:
1. Management review
2. Supplier selection

Instructions are then developed if any operations require subsequent in – depth information to ensure they are performed correctly. These instructions could include special operations performed as an assembly operation, job – specifi c instructions, or a fi ling directory for the confi guration management systems documents and/or records. An example of such are the following:
1. List of quality records and what should be recorded during operations
2. Storage of quality records instruction and ease of fi nding the information

Organization and fl ow diagrams will be helpful to explain 1) how the fl ow of information moves through the company and 2) the responsibilities to perform specifi c operations.

It is important that the quality manager reports directly to senior management and the president/CEO, not the plant or production manager. This structure allows the quality manager to demonstrate an unbiased responsibility for product approval, to give guidance and support for improving quality operations, and to ensure no nonconformance product is shipped to a customer. The functional relationships for business operations in the fl ow and control of quality operations. Based on these operations performed by the designated personnel, a total quality process control fl ow diagram of operations through a company is presented.

The typical business operation begins with the request for quote (RFQ) and concludes with the shipping and billing of the product. In some situations, as with an original equipment manufacturer (OEM), service support may be required. Service support depends on the product and customer, and if a problem develops, the supplier may be obligated to provide support to solve the problem. It is important that all operations required for the program are identifi ed and mapped out, which include the requirements of equipment, labor, procedures/ instructions for the manufacturing operation, training if necessary, and methods to verify that the required results are obtained for each operation.

Records must be kept with the correct forms, and the means to generate and record their input into the system are determined for each operation. All sizes of in – house and custom molders, even with only one or two machines, must document the manufacturing data for control of the process.

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