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Original Date: 02/19/2007
Revision Date: / /
Information : Common Failure Review Board Process
Raytheon’s Network Centric Manufacturing Center in Largo, Florida, has standardized a process to correct manufacturing failures based on Six Sigma methodology and root cause analysis. Giving ownership of problems to a local root cause corrective action team now provides management the best and most cost-effective technical solutions, which has enabled Raytheon to promptly collect, analyze, prioritize, and alleviate manufacturing failures.
Prior to 2003, Raytheon’s Network Centric Systems (NCS) Largo, Florida, Manufacturing Center did not have a common failure review board process in place. This resulted in a nonstandardized approach to problem resolution of manufacturing failures. There were a large number of participants in the problem resolution process at this time who were not localized to the Largo Manufacturing Center, which caused a communication discrepancy among key players. Solutions to most manufacturing failures were not data-driven, and the root cause of problems was frequently never discovered.
Raytheon Largo has developed a standardized method to analyze and correct manufacturing failures based on Six Sigma methodology. This process incorporates tools that include database tracking of failures, Web-based collaborative work environments, pictorial representation of failure points for a system, the development of root cause corrective action (RCCA) or tech team working groups, and the implementation of trend analysis to prioritize failures.
By implementing this new process, the company is able to attain rapid and accurate problem resolution. The root cause of failures is now documented and shared through a Lotus Notes database. There is also accountability and ownership of each manufacturing problem that was achieved by creating the RCCA working groups. By using a standard method, Raytheon no longer has multiple employees trying to solve problems independent of one another. The most important benefit to the Largo facility is being able to identify the root cause of failures and ensuring analytical problem resolution with thorough validation to prevent recurring defects.
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