Quality Metal Products
“We really needed to focus on quality. It’s in our name, but the rules have changed.” The rules referred to by Jo Ellen Dunbar of Quality Metal Products, involve requirements that many multi-nationals place on key suppliers to substantially reduce the number of defective parts. As a tier-one producer of engine components for construction equipment, QMP had to dramatically improve delivered quality, or risk losing business from its principal customer.
Dunbar and her team started the quality transformation journey by engaging IMEC specialist to help solve a problem with its Production Part Approval Process (PPAP). IMEC helped QMP integrate ordering data into the manufacturing system, accelerating the ability to respond to a purchas order and expedite shipment. Advanced Product Quality Planning training helped QMP ensure that parts could be manufactured to the customer’s drawn specification. Root cause and process control methods were deployed to identify quality issues at the source, an instructional process boards were placed next to work cells. Concurrently, the company worked with IMEC and QMP’s main customer to map QMP’s value streams and eliminate wasted, non value steps. To rationalize its 8,000 part numbers, QMP developed a wireless supermarket replenishment system to move product in sequence and keep inventories level.
- Parts per million defect rate down to 187 from high of 3,000
- 100% PPAP delivery
- 95.6% on-time delivery