Original Date: 06/05/2006
Revision Date: / /

Rockwell Collins has implemented a designated self-inspection program that trains and certifies production personnel to perform in-stride inspection of their own work. Employee performance is tracked by both documenting inspection results and by random surveillance inspection. This program has resulted in a significant reduction of workmanship defects associated with customer returns.

Rockwell Collins manufacturing has a goal of building quality products without incurring the cost of non-value- added operations, processing steps, and rework. This goal was addressed prior to 1991 through 100% inspection of post-processed material by dedicated quality inspection personnel. Defective or nonconforming items were returned to the appropriate personnel for rework.

In 1991, Rockwell Collins implemented a program known as the Surveillance-Through-Excellence Program (STEP), an initiative that emphasized the elimination of non-value-added operations, queues, process steps, and rework activity. Its basic elements included operator ownership and awareness achieved through a comprehensive training, qualification, and surveillance program. In 2002, this effort was enhanced and elevated to the Designated Self- Inspection (DSI) Program. DSI includes the key tenets of STEP and the direct alignment with lean electronics and cellular manufacturing objectives through the inclusion of team concepts.

Under DSI, operators receive extensive training in accordance with Rockwell Collins quality management specifications. Operators must demonstrate defect-free performance for a period of 20 working days, after which they undergo and complete the qualification process. Once operators are qualified, they perform self-inspections according to guidelines provided within the individual work instructions and are subject to random surveillance inspections. Operators are required to post the results of their self-inspections, which are evaluated with the surveillance scores. Operators who fail to maintain minimum requirements have their qualifications removed and are subject to remediation and 100% external inspection.

Rockwell Collins insists that DSI support lean electronics and cellular manufacturing by promoting employee ownership and pride, which results in better product at reduced cost. This approach has shown an improved customer acceptance rate of 99.7% in 2005 and reduced workmanship defects in customer returns from 14% in 1997 to 3% in 2005.

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