Original Date: 05/12/1997
Revision Date: 01/18/2007

Cincinnati Milacron’s Machine Tool Group (MTG) has developed and implemented a Dynamic Quality System based on the documentation of all processes, conformance measurements, and continuous improvements. Until about three years ago, the MTG’s quality system was poorly documented, poorly controlled, and haphazard. Besides lacking trained auditors, the system had no formal method for handling non-conforming material; corrective and preventive action; or internal control.

Cincinnati Milacron’s new approach to quality began in 1994 with the objective of becoming ISO-9001 certified. The Dynamic Quality System was designed to be a fully-documented system with processes for internal auditing, corrective action, non-conforming material, and machine audits. The system is based on the corporate vision and supports the MTG Quality Policy, which focuses on customer satisfaction, conformance to requirements, and continuous improvement. Figure 2-5 shows the structure of the Dynamic Quality System.

The focal point of the system is the quality documentation system. Over 300 documents containing policies, manuals, operating procedures, and work instructions are available on-line and in hardcopy at 30 quality documentation centers located throughout the facility. The on-line system uses a commercially-available documentation software program. The combination of the on-line and hardcopy documents ensures that essential information is accessible to everyone who needs it and can be easily updated. Operating procedures and work instructions are available for all equipment and processes in the plant. All work is considered a process and must be documented.

The quality documentation system is reinforced by an effective internal quality audit process. Nearly 50 internal auditors have been trained. They operate in teams of two, and conduct internal quality audits of key functional areas and processes. Annual audits cover all ISO-required elements and help ensure that the company’s ISO certification status is maintained. All audit non-conformances are analyzed to determine root causes, and appropriate corrective action is initiated.

The MTG has closed-loop processes for corrective action requests, non-conforming material, machine audits, and customer satisfaction. Corrective action requests and non-conforming material reports must be closed out within 30 days. Machine audits and 24 to 40 hours of reliability and verification testing are done on each machine before it is shipped. These processes form feedback loops (Figure 2-6) to all levels of the company from the supplier chain to equipment in the field.

Cincinnati Milacron’s Dynamic Quality System provides clearly defined documented policies and procedures, and a baseline for continuous improvement. Well-defined methods for handling corrective action, non-conforming material, and performing audits are clearly specified. The system provides internal control of conformance to requirements; allows for flexibility and variation; and provided the basis for successful achievement of ISO-9001 certification in April 1996.

For more information see the Point of Contact for this survey.