Here’s the situation: You have a part that you’ve been making and selling but you’ve decided to put it out to quote. You send your drawings package and samples of the part to a contract manufacturer that has a status for providing quality engineering support. In reviewing the drawings, the project engineer picks up on a small but significant difference between the drawing and the actual part that’s in production.
This points to a couple challenges:
The company’s documentation is incorrect.
The tool is incorrect.
The right part isn't being made to spec.
Obviously, the discrepancy between the drawing and the part wasn’t a difference-maker since nobody noticed it before. But is that any way to do business?
Think about it: Somehow a tool was made that didn’t conform to the drawings and NO ONE EVER CAUGHT IT. Quality processes are part of any trustworthy contract manufacturer’s operation. For example, the Production Part Approval Process (PPAP), which acquired its roots in the automotive industry, is among the most norm in production across industries.
The PPAP is made to demonstrate that the look and production process produced by the supplier will meet up with the client’s requirements as decided to in the look phase or in the drawings package. When used correctly, the PPAP minimizes the chance of failure, reduces costly mistakes and moves the project forwards in a timely fashion.
Don't Just Repair the Blame, Fix the nagging problem
In the entire case of our scenario, something slipped through the PPAP record clearly. This could property on the desk of many departments - quality, engineering, administration. Perhaps a box was checked when it will have been through further review unintentionally. While it’s important to execute a post-mortem on what and just why it occurred, it’s a lot more vital that you follow established procedures to make sure it doesn’t happen later on.
From the customer’s perspective, keep in mind this is your project. It’s incumbent upon you to become engaged in the process and guard the integrity of your project.
Before you sign off on a PPAP:
Carefully inspect every tool sample against the drawings. Does it look as it should?
Carefully inspect every product sample against the prototype and/or drawings.
Document and statement any discrepancies immediately. Take photos and provide a detailed explanation of the differences.
Cautiously read every document you get from your CM before you sign.
Tap Into the Power of Engineering Support
There are many benefits of working with a CM that offers engineering support.
The customer's goals are front and center. A good engineering team will listen and ask questions, then translate the customer's objectives into clear specifications for the manufacturing team to execute.
Because 80 percent of the cost of a product is determined through the design stage, early involvement by engineers may ensure that there are zero “hidden factories” - the hidden price of quality versus the visible costs of quality.
Engineering expertise helps customers know very well what it takes to produce, in order to consider the manufacturing process if they design their products also.
They know Good Production Practices (GMP) and will ensure the part has been made at the best quality for the cheapest cost.
Have a variety of experience in a number of specs typically, materials, and test requirements.
Here is a graphic that visualizes the process of design, review and manufacturing. Note the arrows phoning for review, feedback and review again. Communication is essential.
If people are involved, mistakes are going to happen. When they do, it’s important to fix them and address them so they aren’t repeated. Help to make it a teachable moment. Take the time to revisit founded quality protocols both on the CM part and the customer side.
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