Ensuring the Quality of the Parts We Make

These days, ensuring quality parts all along the supply chain is a major concern for logistics managers. In previous posts we’ve discussed the problem of substandard (or even counterfeit) parts sneaking into the supply chains of otherwise reputable vendors. So we thought we just might spend a moment to blog about our efforts to police our own territory, so to speak.

At Perfection Spring & Stamping Corp., a global supplier of custom metal stampings, springs, wire forms and assemblies, we consider quality to be one of our strengths. We have a documented DPPM (Defective Parts per Million) rate of 0.67 parts after manufacturing 88 million pieces.  We’ve even dedicated a section of our website to documenting the level of care we put into our quality assurance efforts, which are considerable, in our opinion.

Our commitment to quality is backed up by third-party certification, ISO/TS 16949:2009, in-line quality control, and Poka-Yoke adaptation to world-class standards. Our quality-management system drives what we do, and how we do it, for every customer. We track, monitor, and implement changes to always improve our goals for delivery, quality, and service. We partner with proven vendors for supply chain, vendor-managed inventory, local warehousing, and JIT delivery.

Quality partsWe adhere to a zero-defect goal to meet the specific quality standards set by our customers. High quality begins with process control and monitoring. We combine real-time statistical process control (SPC) with comprehensive statistical analysis for every part we produce. This process includes pre-planning evaluation, in-line process control, and off-line technical support. Our quality methodology adheres to Advanced Product Quality Planning practices. Each part we manufacture follows a standard quality approval process to establish confidence in the production plan, process, and method. This system works to ensure engineering design records are maintained, specification requirements are properly adhered to, and the manufacturing process is repeatable while consistently meeting all printed requirements. We share the data and results for every part we manufacture with our customers.

Our standard production part approval process consists of 18 elements, modified based upon customer-specific requirements or product specifications.

  1. Design Records
  2. Authorized Engineering Change Documents
  3. Engineering Approval Change Process
  4. DFMEA (Design Failure Mode and Effect Analysis)
  5. Process Flow Diagrams
  6. PFMEA (Process Failure Mode and Effect Analysis)
  7. Production Control Plans and Bill of Materials
  8. Measurement System Analysis Studies
  9. Dimensional Results
  10. Records of Material and Performance Tests
  11. Initial Process Studies
  12. Qualified Laboratory Documentation
  13. Appearance Approval Reports
  14. Sample Production Parts
  15. Master Sample Retention
  16. Checking Aids/Gages/Fixtures
  17. Adherence to Customer Specific Requirements
  18. Part Submission Warrant to the Customer (PSW)

We also employ a range of quality assurance and manufacturing methods which include:

SPC (Statistical Process Control): This is an effective method of monitoring a process through the use of control charts, which enable the use of objective criteria for distinguishing background variation from events of significance based on statistical techniques. Much of its power lies in the ability to monitor both process center and its variation about that center. By collecting data from samples at various points within the process, variations in the process that may affect the quality of the end product or service can be detected and corrected, thus reducing waste as well as the likelihood that problems will be passed on to the customer. With its emphasis on early detection and prevention of problems, SPC has a distinct advantage over quality methods such as inspection that apply resources to detecting and correcting problems in the end product or service.

“5S” Methodology: This is a philosophy and a way of organizing and managing the workspace and workflow with the intent to improve efficiency by eliminating waste, improving flow, and reducing process unevenness. This is accomplished through Sorting, Straighten, Shining, Standardizing, Sustaining and Safety (5S).

Poka-Yoke: Fail-Safing, Foolproofing, or Mistake-Proofing, a method of preventing errors by putting limits on how an operation can be performed in order to force the correct completion of the operation.

We think that this substantial level of quality assurance helps to distinguish Perfection Spring & Stamping Corp. from our competition.  It’s what our customers call “The Perfection Advantage”.

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