Defect Prevention
Here at OSE, we understand the importance of preventing defects instead of removing them after production. Our proactive mindset ensures that no time or resource is wasted on unnecessary problems.
Process Design and Audit
Our manufacturing processes are designed to minimize the defects passed on to the next stage. Our processes are frequently audited and improved to ensure compliance and performance. Our array of in-process testing equipment and procedures form the basis of our overall process design strategy.
For example, the production of server motherboards employ the following general procedure, where multiple quality checkpoints ensure that no defect will reach shipment.
Operator Verification
In a high-mix production environment, where many products coexist and process change-overs are frequent, it's especially important to implement a system to verify the qualification of operators.
At OSE, each individual operator is trained and retrained annually for a particular array of tasks to ensure an acceptable degree of specialization and expertise. To ensure the correct assignment of operators to tasks:
- Shift managers have access to a comprehensive matrix of operators and tasks such that only qualified operators are assigned;
- Operators are required to wear tags indicating their qualifications, such that process auditors and engineers can easily confirm the qualification of a working operator.
Statistical Process Control
For repeatable processes such as dimension measurements and failure rates, we employ standard statistical process control techniques to ensure operations are within normal parameters.
- Advantages of employing SPC are twofold at OSE:
- Constant monitoring ensures that engineering staff can be immediately alerted when a problem arises;
- Data collected are archived often indefinitely, such that they become valuable tools in future analysis towards evaluating new process improvements.
Continuous Improvement Programs
We believe that quality is not just about following established rules; we must also always seek lower-cost and lower-risk solutions. Our operators, engineers and managers continuously find ways to circumvent defect-inducing elements of our process.
Continuous improvement is ingrained upon the culture of OSE. Activities such as quality contests between different production groups and monthly improvement presentations ensure that team members are always recognized for their efforts.