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The quality cycle we implement and follow to resolve most problems is CACCOS ™: Collect, Analyze, Connect, Create, Optimize & Succeed. From R&D to optimization of manufacturing, process upgrades, continuous quality improvement, cost and waste reduction CACCOS is our most efficient tool to find and implement the optimal answer you are expecting from us..
 
Ishikawa 
A Simple excel sheet to manage brain storming sessions and automatically create a Fishbone from a standard Excel Sheet.  The powerful tool to make brain storming session more interactive and productive.

The inputs are entered into this "standard" excel sheet

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Ishikawa

The worksheet automatically transfer these inputs into this Ishikawa diagram

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Selection Matrix

To optimize quality of decision by calculating “Attractiveness”: the weight average of each numerical or qualitative  input.

Selection Matrix
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Effect of Process Improvement (here above) on Raw Material Usage

Process Optimization,  a key component of which , is illustrated here above generally brings many other benefits like increased customer satisfaction and Cost Reduction (here below due to lower raw material usage).

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On Going Correlation Studies - a Driving Force for Process Improvement

Data Collection is nearly always the first step of any improvement process. The example demonstrates that by recording data the right ways it is possible to automatically extract value  from them.

Data tables (like here below) below can be formatted and  designed to be automatically fed and continuously run correlation analysis. Here  monthly average  for process parameters are recorded with a key process output: % of first acceptance (when 1005 = Zero % rerun).

Following this system, without extra work,  DOE results can be derived directly from production data.

This approach that allows to always set process parameters for optimum process output is very powerful and combined with optimization of all steps of the manufacturing process can result in hundreds of time rejection rates.

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PhosRawMatUsageReduction

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Connecting  databases to extract key information

By connecting multiple data base data from several plants word wide (chemical raw material purchasing, production throughput, part design ...)  we create the synthetic and meaningful information that can be used for critical decision making .

In the example (on left)  two plants should bench mark the first one to reduce their chemical treatment cost. The cost of third plant is 4 times more than the hundreds of thousand in the first plant!

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