VÄGEN TILL RÄTT KVALITET - på inköpta komponenter En fallstudie på Gambro Lundia AB Monitor Division

Abstract

To avoid incorrectly manufactured components, the modern quality development
focus towards preventive actions and process improvements. Therefore, a
function as acceptance control is not of particular interest.
This report treats the activities that have to take place at Gambro Lundia Monitor
Division, GLAB MD, in order to get satisfactory quality of purchased
components. The Incoming Inspection inspects the majority of components, but
still most deviations are found in the Production. The purpose of this master
thesis is therefore to propose how the Incoming Inspection should be changed,
and suggest what kind of preventive activities that should be used. With this in
mind, the defensive quality control, Incoming Inspection, is not a long-term
solution.
By way of introduction, a careful examination of the organisation and
assignments of the Incoming Inspection has been performed. Furthermore, an
overviewed study of interfaces of the department was made. In these studies
interviews were especially applied. The interviewed actors were also asked about
their opinions and were given the opportunity to suggest proposals for
improvements. With a view to get further ideas for improvements, five other
companies have been examined. One company that is carrying on a well
functioning Incoming Inspection, and one that is only working with preventive
activities. In the three last companies, both these aspects were studied, but not as
thoroughly as in the other two companies.
From the present situation at GLAB MD, five main shortcomings have been
identified. Batches with incorrect located components, both functional errors as
well as esthetical errors, can, when applying AQL, nevertheless be accepted. The
procedure also obstructs continuous improvements. It is impossible to examine
every parameter due to insufficient resources. Consequently it is important with
decisive checkpoints in order to avoid an inefficient production due to an incorrect
decision of the quality of the incoming batches. Even the handling of incorrect
components is essential for how suppliers regard GLAB MD’s view of quality.
Correct specifications are important when making accurate decisions, both for the
suppliers and for the co-workers of the Incoming Inspection. Otherwise an
inefficient production can occur. At last, but not least, insufficient use of quality
tools, for example FMEA and capability study, lead to deteriorated knowledge of
the supplier’s production.
iv
To achieve satisfactory quality of purchased components, our final conclusion is
that two main activities have to take place. A reconstruction of GLAB MD’s
Incoming Inspection must be carried out before any reduction can occur, in
order to keep control of quality of the purchased components. At the same time
preventive activities have to be carried out, because this process is long. We have
found that GLAB MD have a great potential to improve these shortcomings,
however it demands a genuine effort from all GLAB MD’s co-workers for this
change.
Our most important suggestions are stated below.
− On the basis of a genuine analysis of risk, all components should be
classified from A to C in order to concentrate the inspection where the
biggest needs are. It is impossible to control every component equally due
to insufficient resources.
− AQL should not be applied since the application does not create an
atmosphere where every deviation is an opportunity for corrective actions
and improvements. Instead the sampling plans should be based on
MIL-STD-1916, which means combining accept-zero with prevention
procedures.
− The four main areas; plastic, metallic, electronic and electro mechanics,
should be considered when checkpoints are created. P-FMEA, both from
suppliers and GLAB MD, and D-FMEA are among things that should be
used in order to get decisive checkpoints.
− The character of the deviation should decide when a complaint has to be
performed. In order to get penetration at suppliers, batches or individual
components should always be returned if located components are marred
by functional errors, and located components with esthetical errors
should be gathered before a complaint is made. Considering that, a plan
of measure should always be required, because GLAB MD’s handling of
incorrect components is now of great importance.
− Capability studies, SPC and P-FMEA should always be demanded in
order to, both in short-term and long-term, obtain knowledge if the
supplier has ability to manufacture components that meet specified
demands. The Incoming Inspection at GLAB MD thus gradually can be
reduced.

• author: Karlsson, Maria and Lövdahl, Camilla
• supervisor: Bertil Nilsson
• organization: Production Management
• course: MIO920
• year: 2003
• type: M1 - University Diploma
• subject: Technology and Engineering
• other publication id: 03/5181
• language: Swedish
• id: 2007519
• date added to LUP: 2011-06-30 16:17:43
• date last changed: 2011-06-30 16:17:43