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PLASTICS-USA PHASE IV: Model System for ISO Implementation Project: ISO Implementation at Plastics, USA December 14, 1999

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Plastics USA Team ISO Implementation Glenn Gee ggee@abcs.com - Project Liaisonggee@abcs.com Cathy Petretich catherine.petretich@worldnett.att.net - Team Facilitator catherine.petretich@worldnett.att.net Team Members Terry Bilke bilke@execpc.combilke@execpc.com Perry Goss tcsi@murlin.comtcsi@murlin.com Alan Stolzerstolzeraj@slu.edustolzeraj@slu.edu

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Plastics USA Contents Introduction Company Background Project Update Project Plan Progress Model System for Implementation Incorporating Team philosophy Data and sampling plan Financial aspects of ISO 9000 Documentation assessment Team Course Evaluation Works Cited Appendix A Appendix B Appendix C Appendix D

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Plastics USA Introduction Project: To help Plastics USA, a small plastics injection molding company, to implement an ISO 9001 based quality system. Team will develop model system for ISO implementation Phase IV describes findings and recommendations

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Plastics USA Company Background Located northeast of Terre Haute, IN 80 full-time workers 3 shift operation Seeks various products to design and produce Company unsuccessfully attempted registration once before Lack of commitment from management Inadequately trained ISO 9000 rep Quality manual and procedures in place Quality manager is working diligently to meet timeline

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Plastics USA Project Update Plastics USA is assessed as follows: Motivation of company medium strength Information and education low (training) Resources involved low, insufficient Planning for registration high With the possible startup of internal audits, it is possible that top management will provide more support in the effort.

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Plastics USA Project Plan Progress Target for registration is 4/1/00 Status of project steps: Management training retraining is planned Develop quality manual registrar will review in mid-January Contract registrars one has been selected and is now in place Sign contract with registrar done Develop procedures ongoing Write work instructions -- ongoing

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Plastics USA Project Plan Progress D-day (start up of system) delayed 1 month Internal auditor training has been accomplished Workforce training memos and briefings done Start internal audits to begin in mid-December ISO 9000 Network audit scheduled for late Jan Management reviews/Pre-assessment by registrar/Assessment by registrar one has been prepared Celebration of registration will be planned

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Plastics USA Role of Class Team Provide support for the implementation effort Provide toolkit ideas for quality improvements Provide critiques for upcoming systems procedures that are being developed Provide critiques for upcoming work instructions that are being developed Provide ideas for possible forms as requested by the company Other tasks or duties as assigned

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Plastics USA Model System for Improvement Four areas were deemed most critical: Incorporating team philosophy Best uses of data/statistical methods Financial aspects of ISO 9000 certification Documentation Assessment

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Plastics USA Team Course Evaluation Evaluation is vital to the success of a team The team has been strengthened by the evaluation process employed Team members are evaluated on a weekly basis on participation, timeliness, and content An analysis of weekly evaluations indicates that the team is functioning at a high level, and has shown consistent improvement (see chart on next slide) Lessons learned have been documented

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Plastics USA Works Cited Bubshait, A. & Farooq, G. (1999). Team building and project success. Cost Engineering. Crosby, P. B. (1980). Quality is Free. New York: Penguin Group. Chapters 1-3 DeVor, R.E, Chang, T., and Sutherland, J., Statistical Quality Design and Control, Macmillan, New York, 1992. Edmunds, T. (1996). Smooth Out the Road to ISO 9000 Implementation, Quality Magazine. Grant, E.L., and Leavenworth, R.S., Statistical Quality Control, 6 th ed., McGraw Hill, New York, 1988.

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Plastics USA Lamprecht, J. (1992). ISO 9000. New York, NY: Marcel Dekker, Inc. McTeer, M., & Dale, B. (1995). How to achieve ISO 9000 series registration: A model for small companies. Quality Management Journal 3 (1), 43-55. McVinney, C. (1993). http://www.michaelsmcvinney.com/articles/sixteen_ways.htm) http://www.michaelsmcvinney.com/articles/sixteen_ways.htm Singhal, V. & Hendrinks, K. The Financial Justification of TQM. Center for Quality Management Journal Sinn, J. Disciplined culture for change: conducting and managing projects. Toolkit B.

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Plastics USA SPC and Injection Molding. http://www.ramat- negev.org.il/~howarda/SPC.HTMhttp://www.ramat- negev.org.il/~howarda/SPC.HTM Stein, S. (1999). A Recipe for Well-Done Procedures, Quality Progress. Summers, D. (1997). The Costs of Quality. Quality. Upper Saddle River, NJ: Prentice Hall Tips for ISO 9000 Preparation: Control Nonconforming Product. Quality Magazine, September 1999. http://qualitymag.com/articles/1999/sep99/0999f4.html http://qualitymag.com/articles/1999/sep99/0999f4.html Rohladner, D. (1999). Effective team building. IIE Solutions.

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Plastics USA Appendices Appendix A Appendix B Appendix C Appendix D

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PLASTICS-USA PHASE IV: Model System for ISO Implementation Project: ISO Implementation at Plastics, USA December 14, 1999