Tag Archives: Quality System Procedure

Lean Manufacturing and Six Sigma

As business and manufacturing has changed over the years, a greater focus has been made by companies to do a better job eliminating waste and redundant processes that are adding cost and slowing down production.  This business methodology is known as lean manufacturing, and it is a systematic method for eliminating waste within a manufacturing system.  At Tella Tool, as a leading custom job shop, with state-of-the-art capabilities, we have been taking steps to implement lean manufacturing as well as Six Sigma.

Six Sigma is a data-driven approach and methodology for eliminating defects in the manufacturing process.   It works by identifying and removing the defects in the manufacturing process, as well as by minimizing the variables that exist in the process that can lead to process delays, and additional costs and expenses.  Developed by great thinkers like Bill Smith, Mikel Harry, Shingo and Taguchi, it has a history of success in creating profitable and efficient companies.  The steps that make up the framework of Six Sigma are as follows:

D – Define

M – Measure

A – Analyze

D – Design

V – Verify

These steps are applied to improving any existing processes to “entitlement”, or perfection

At Tella Tool we have been working to implement the Six Sigma methodology to streamline our processes and make our business more efficient.  We started by reviewing our historical data, and then created a plan to collect baseline data that will be used to gage the project’s success.  An overview of process mapping, data types, operational definitions and measurement system analysis was worked on to create a foundation to work with.  A process map was created which was verified by walking through the process on the manufacturing floor, also known as GEMBA.  By walking the floor and observing the processes in action, many ideas were conceived and additions were made to our lessons learned log.  We also have learned the importance of operational definitions and data collection plans, which have helped to uncover many unknowns that would have created trouble late in the collection phase, rather than now when it is easy to change in the planning stage.

While changes to implement lean manufacturing and Six Sigma are ongoing, the benefits to our long term business will be immense.  To learn more about our manufacturing process improvements, and about capabilities, contact us here.

Earth Day 2016

While the world may be divided up into many different countries, each with their own unique set of conflicts/issues, one concept is universally accepted:  we all share this one planet Earth and we all have responsibility to help take care of it.  Each year this fact is recognized with the global celebration of Earth Day, an annual event celebrated on April 22.  On this day, from the corporate level down to the individual level, events are held worldwide to demonstrate support for environmental protection.  The goal of the day is to bring global attention to the critical nature of protecting our planet and to foster unity in addressing this issue.

Earth Day 2016

At Tella Tool, we support Earth Day and are committed to continuous improvement in our policies relative to environmental protection. We are compliant to the standard ISO 14001-2004 and registered with Smithers Quality Systems. ISO 14001-2004 is a family of standards pertaining to environmental management that help companies conserve vital resources and prevent pollution.  By becoming compliant to these standards, we are able to reduce operating costs via improved efficiency and waste reduction, improve the health and safety conditions for our employees, and reduce the risk of environmental liabilities.  These practices help us to be part of the solution, rather than part of the problem, as it pertains to environmental pollution.

To maintain the focus of continually improving on our environmental policy, we have developed and implemented an annual training plan for our plants.  This assures that new employees, as well as long-term employees, are all up to date on company expectations.  We also utilize the Globally Harmonized System of Classification and Labeling of Chemicals (GHS) which sets the criteria for the classification of health, physical, and environmental hazards, as well as clarifying what information should be included in safety data sheets and on the labels of hazardous chemicals.  Additionally, we offer “Bloodborne Pathogens Training” to our employees to be certain they receive information related to bloodborne pathogens and diseases, methods used to control exposure in the workplace, vaccinations and medical evaluation information and post exposure follow-up procedures.  Future Tella Tool environmental plans include investing in the purchase of a compactor to reduce the size of the waste material we produce.  All current and future initiatives ultimately contribute to putting into action our commitment to the environment.

Taking a firm stance on environmental issues is something we take seriously here at Tella Tool.  As a leading job shop with state-of-the-art capabilities, we believe in being at the forefront of the effort to promote environmental protection.  By setting and adhering to high standards for ourselves, we hope to set an example for other companies…..because it will take the efforts of all companies and all individuals to tackle the responsibility of caring for our great planet, Earth.  To learn more about our manufacturing capabilities and/or our environmental policy, please contact us here.

Tella Tool Has a New ERP System

As technology improves, companies must adapt to stay current with the times, and take advantage of new ideas and solutions that will improve their business.  Here at Tella Tool we have recently taken the step of adding a new ERP system from Plex which will give us a single platform for all of our ERP operations.

ERP stands for Enterprise Resource Planning, and is a business process management software that allows a company to integrate back office functions related to technology, sales and human resources.  At Tella Tool, we chose a cloud based ERP system so we would have a system that is accessible to us anywhere in the world at any time.   The centralized service and infrastructure saves us from having to host the system on internal servers which we would have to maintain, and allows for regular updates for security and maintenance purposes.

One of the biggest advantages of implementing this new system was the ability to have customer interaction in real time.  We can now perform transparent EDI transactions with our customers in the new system without the need for any additional external software.  In our new ERP system, we also now have all the sales tracking software we need to track leads, and save and view our customer’s purchase history with us.  The security of our new system is top of the line, from ironclad firewalls to automated security sniffers that make sure our data and our clients data is always secure.

Our new ERP system also gives us the ability to collect and integrate plant floor data including up time and downtime in one easy system.  We can also monitor efficiencies and keep track of inventory easily with it.  With the Manufacturing Execution System (MES) built into the ERP system, we can now connect every machine, device or console on the plant floor to the system, forming a cloud-based backbone that removes the need for third-party software and allows for new features and functions to be rolled out which keeps both Tella Tool and its customers on the leading edge of technology.

As a leading custom job shop, with state of the art capabilities for tooling, stamping, fabricating and machining, moving to a new ERP system with Plex is the next step in providing excellent service for our customers.  For the latest company news and updates follow us on Twitter and LinkedIn.

ISO Certification – Everything You Need to Know

If your company wants to get ISO certified, there are several steps that need to be followed. When followed in order, you can implement a quality ISO process for your company, regardless of what industry you’re in or how big the company is. When you have your ISO Certification, customers will know you are serious about your business and employees will better understand processes in place for quality or organization.

After determining you want to be ISO Certified, it’s important to think about what exactly you want to get out of your certification. Things to consider are quality, customer satisfaction, profitability, and more. After deciding what areas to target, it’s important to implement the proper documentation, in accordance with the standards set forth by ISO. For example, you’ll need a Quality Manual and also Quality System Procedure documents. There are generic documents you can purchase and adjust as needed or you can hire a professional to construct the right documents if you need to get more specific.

With documentation in place, train employees with the new standards. Since not all employees may be affected by all aspects of the new guidelines, train accordingly. In order for the ISO to be as successful as possible, it’s important to make sure everyone is on the same page.

When you have completed these steps, it’s time to find a registrar. There are many registrars, so if you don’t know one you may want to consider using one that has worked with your type of industry before. Although this isn’t paramount, it can make things faster. After having used your new system for several months, you can set up a date and time to get a certification audit. You will want to make sure everyone is properly trained before getting certified and that you have any documentation, such as inspection or training records, readily available.

When you have done all of this, it’s time to get certified. Customers who see an ISO Certificate hanging on your wall will know your company cares enough to keep up with industry standards and that your service and/or products will meet their expectations.