Original Date: 02/19/2007
Revision Date: / /
Best Practice : Regressive Flow/Structured Quality Information Data System
The use of regressive flow tools has given Raytheon’s Network Centric Systems Manufacturing Center teams the ability to identify the problems that are costing the most money and labor. The Largo, Florida, facility has shown steady improvement in regressive flow over the last four years, leading to bottom-line savings.
Prior to 2003, Raytheon Network Centric Systems’ (NCS) Manufacturing Center in Largo, Florida, was not obtaining data on manufacturing products that were being reworked, reinspected, and retested (also referred to as regressive flow). Raytheon’s focus was on nonfinancial quality metrics such as yield and failures per unit. There was no insight into the cost of these issues or the resources expended in solving these problems. Raytheon had no data analysis tools to link failures to dollars spent correcting them, resulting in a lack of program focus and the inability to identify and resolve systemic problems.
In 2003 Raytheon Largo initiated a plan to capture data utilizing the Structured Quality Information Data System (SQUIDS). SQUIDS compiles data in the areas of rework, reinspection, retest, troubleshooting, and data pertaining to engineering change notifications. This information enables teams to focus on the problem areas dealing with regressive flow. Year-to-date regressive flow issues improved 58% from inception in 2003 to January 2007 (Figure 2-6), a testimony to the success of the regressive flow analysis tools that provide program visibility, while the available data can link a dollar figure to assembly, inspection, and test. It also provides improved prioritization capability that focuses on how much is being spent and where it is being spent. This provides Raytheon with an overall site picture as well as individual program performance metrics. SQUIDS is able to link regressive flow activity to product indenture level (system, unit, module, CCA) and identify the category of failure that caused the regressive flow, enabling Raytheon Largo to prevent costly rework efforts (Figure 2-7).
Figure 2-6. January 2007 YTD Regressive Flow
Figure 2-7. Regressive Flow/SQUIDS
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