Figure 1

Business Process Improvement Results Shared by Current Users

Solumina Supplier Quality Management System enables a new systematic and dynamic approach to managing quality with suppliers.

Solumina provides a complete paperless system for defining, managing, communicating and verifying product specifications and requirements with suppliers. Quality can be managed at the supplier efficiently down to the characteristic level with processes that parallel the internal processes.

Quality Engineers plan product and inspection specifications, which include product characteristics, tolerances, and rules for sampling, oversight and audits. First Article Inspection (FAI) requirements are specified in compliance with FAA and AS9102 guidelines.

SOLUMINA SQA SOLUTIONS

1

Minimize Inventory in Receiving Inspection

Solumina’s collaborative quality approach enables

more inspections to be performed at the supplier

site via the web instead of inspecting after receiv-

ing. Inventory items in receiving inspection are

minimized. Products can ship directly from the sup-

plier to work-in-process at the plant based on the

supplier’s quality rating for the specific part and the

rules established by quality managers.

Minimize the Need for Third-Party Contract Inspection

Solumina provides the ability to remotely review

and approve source inspection data including mea-

surements, check lists and certifications. Inspec-

tions and audits can be performed at the supplier

site by customer, supplier, or third party contrac-

tors as specified by the quality manager for each

supplier and part. The application provides a sys-

tematic way to manage the oversight of source in-

spections performed by suppliers in order to mini-

mize the need for third party contract inspection at

the supplier’s facility.

Quality issues are identified earlier at the supplier

site and corrected before shipment of goods is au-

thorized. Quality issues that escape and are found

downstream during the assembly process, have a

greater impact on the supplier’s metrics, and trig-

ger containment and Corrective Action.

Improve SupplierPerformance

Reduce Cycle Time forSupplier Issue Resolution

Reduce Inventory inReceiving Inspection

Reduce Admin andContract Inspectors

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2

Eliminate Manual Management Tasks

Receiving inspection, source inspection and suppli-

ers can perform all necessary transactions via the

web. But Solumina’s Supplier Quality Assurance

system does more than deliver forms to suppliers

via a web portal. The system dynamically generates

inspection and audit requirements for each PO line

item based on the most recent history for the spe-

cific part and for the specific supplier.

As supplier quality increases, the system relaxes

oversight requirements based on pre-established

inspection oversight rules for different types of

parts. Conversely, the system tightens inspections

and oversight as defects are found either at the sup-

plier location, or downstream during the assembly

process. The automation of oversight rules elimi-

nates the need to manually manage intervention

and ensures that all suppliers are managed consis-

tently.

Users are stepped through check lists and data col-

lections, which can be configured to branch based

on user answers. In-process recorded measure-

ments and observations trigger instant feedback on

out-of-tolerance and out-of-control conditions.

Reduce Cycle Time to Resolve Supplier Issues

Users can document Discrepancies at the source, at

Receiving, or when an escape is found on the shop

floor. Solumina includes a completely integrated

discrepancy documentation, classification, disposi-

tion, and Corrective Action system.

Every manager, engineer and production mechanic

strives for zero defects, but the reality is that discrep-

ancies and defects happen. Real-time communica-

tion between suppliers and buyers make it possible

to react quickly to disposition issues when they arise

on the shop floor. The Solumina system continuous-

ly monitors quality based on inspection results and

provides a methodology to continuously improve

quality. When repeat escapes are found, the system

initiates containment and Corrective Actions.

Improve Supplier Performance

Supplier performance management is critical to

controlling production costs, reducing variance,

and protecting the quality standards associated

with the brand name.

Solumina provides the capability to query real-time

supplier status, constraints, and history records

for all processes and activities related to product

quality and production history. Graphs and reports

include inspections, supplier ratings, DPPM, and

discrepancies.

Solumina enables a self-managed quality path for

suppliers, which increases awareness and owner-

ship of process strengths and weaknesses. The col-

laborative quality system provides the supplier with

an easy to use tool to help diagnose which processes

need the most attention.

Solumina Supplier Quality Assurance includes these features:

• Configuration-managed product characteristics, inspection re-quirements, and rules for sampling, oversight and audit

• Generative Inspection Planning

• Sampling and oversight plans with rules for automatic sample size adjustments based on each supplier’s part history

• Records for all processes and activities related to product quality

• Real-time communication among suppliers, buyers and quality managers

• Two-way communication for inspection results, supplier rating, DPPM graphs, discrepancies and corrective action

• Dynamic inspection requirements for each Purchase Order based on supplier performance

• Online Verifications and Characteristic Data Collection

• Discrepancy report, Issue/Defect Containment Holds and Correc-tive Action Requests

• Quality analysis tools that provide a self-managed path for suppliers

• Strict rules for compliances with AS9102 First Article Inspection requirements

• Gradual transition of more component inspections to the supplier

Figure 2

Verifications and Characteristics Tied to Requirement, Part or Supplier Part

Solumina’s Supplier Quality Assurance functionality can be used by itself or coupled with other Solumina quality management functions used to manage internal production operations. The Solumina suite of software solutions provides a comprehensive quality management solution for your organization.

SOLUMINA SQA FEATURES

3

Product Specifications

Solumina provides organization and management

tools to develop a library of product specifications,

process specifications, inspection requirements,

and rules for sampling, oversight and audit. These

dynamic inspection and verification requirements

are dispatched over the web to the supplier site for

each purchase order line item. All inspection data

collection is recorded in Solumina and can be used

to determine which areas need to be enhanced, and

which suppliers require additional oversight or

Corrective Action.

Inspection Planning

Solumina provides a central location for the author-

ing and maintenance of inspection requirements

for product key characteristics and verifications

for process requirements including handling, la-

beling and packaging. Characteristic measurement

requirements include upper and lower spec limits

and sampling rules. Inspection and verification

specifications can be set at hierarchal levels with

the following override capabilities:

• Standard Requirement Group

• Part Family Specific

• Part Number Specific

• Supplier/Part Number Specific

Sampling Plans

Each measurement or observation characteristic

is assigned a sampling plan that determines the

frequency and sample size for each inspection.

For example, characteristics that are considered

critical can cause 100% of all associated parts to be

sampled and inspected. Characteristics considered

minor can cause a smaller percentage of parts to be

sampled and inspected.

Each sampling plan can optionally include switch-

ing logic that defines rules for automatically switch-

ing to a tighter or more relaxed sampling plan based

on recorded failure history. Inspection items or

characteristics with no issues gradually receive less

attention while trouble spots receive more scrutiny.

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Figure 3

Verification Requirements at the Source,

Receiving or Both

Figure 4

Supplier Quality Performance Metrics

Include DPPM

4

Process Control

The process control features assure that all verifi-

cations are performed and documented in the pre-

scribed order, that inspectors have the proper cer-

tifications to perform certain inspections and data

collections, and that the latest characteristic mea-

surement and sampling requirements are applied

including the type of gauge required.

Purchase Order Information

When an inspector logs onto Solumina, all rel-

evant open purchase-order line items appear in a

dispatch list. On command, each purchase order

generates a corresponding Inspection Order whose

instructions are based on current characteristic, in-

spection, and sampling requirements. All require-

ments are in full view including specification limits,

criteria, and inspection method details.

Online Verification and Data Collection

The Inspection Order includes all characteristic

data collections that must be performed. The user

interface makes data entry easy by prompting the

inspector for each check list item, observation, and

measurement required. When inspectors log on to

the system, they quickly return to where they left off

in the Inspection Order.

Solumina lets the inspector know what data collec-

tions remain before the inspection can be complet-

ed. The system also alerts when entered values are

out of range.

Optimized Inspection and Audit Oversight

Certain suppliers will require more inspection over-

sight than others. Solumina randomly determines

which Inspection Orders will be selected for over-

inspection based on each supplier’s historical and

recent quality performance. The system ensures

that the over-inspection is performed by an Inspec-

tor different from the one performing the primary

inspection.

First Article Inspection

When Purchase Orders indicate that there is an

open First Article Inspection (FAI) or FAI Delta

requirement, Solumina ensures that the next In-

spection Order is flagged accordingly and contains

all the requirements for the FAI in full compliance

with AS9102 requirements. The FAI requirements

must be completed before any units can be shipped

to the buyer.

Figure 5

Supplier Portal for Two-Way Communication with Suppliers via the Web

5

Supplier Quality Analysis Tools

Supplier performance management is critical to

managing production costs, reducing variance, and

protecting the quality standards associated with

brand names. In Solumina, each supplier’s perfor-

mance is tracked consistently with full visibility of

all supplier-induced issues and defects found dur-

ing inspection at the source, or as an escape down-

stream in the manufacturing process. Solumina

displays quality performance metrics in easy-to-

read charts and reports that can drill down all the

way to the specific Purchaser Order and inspection.

Suppliers with a high defect or failure rate are high-

lighted.

Discrepancies

Discrepancy and defect reporting are fully integrat-

ed and initiated directly from an Inspection Order.

The inspector is required to initiate a Discrepancy

report if any of the characteristic data collections

are rejected or out of limits. Discrepancies are au-

tomatically routed to the appropriate personnel.

Discrepancies caused by a supplier will affect the

supplier’s performance rating.

The disposition, review and approval workflow is

configured to handle complex routing requirements

for different types of discrepancies. Communica-

tions further complement the process, document-

ing review and discussion threads.

Discrepancies and defects are classified by respon-

sible processes, defect types, symptom types and

cause types. Analysis of defect classifications pro-

vides the basis for needed Corrective Actions.

A unit’s disposition can include instructions to re-

work, repair or scrap the unit. A defective installed

component or subassembly can be fixed in place or

removed. The defect moves with the removed com-

ponent. The removal history stays with the assembly.

Benefits:

• Improved component parts quality

• Fewer quality escapes

• Least inventory in receiving inspection

• Minimum third party contract source inspection

• Lower sourcing and warranty administrative costs

• Reduced inspection and audit oversight cost

• Quicker issue disposition and corrective action

• Increased supplier ownership of process strengths and weaknesses

6

Figure 6

Defect Containment is Automatically Flagged

until Correction Action is Verified

Figure 7

Corrective Action Initiated from

Discrepancy Report

Quality Suspect and Defect Containment

Defect containment Holds prevent further ship-

ment of suspect parts without verified Corrective

Action, over inspection, or explicit approval. Alerts

are immediately placed on all affected Inspection

Orders. Visibility of Holds is never lost throughout

the process.

Solumina includes various types of Holds includ-

ing “red decal” Holds which identify an item that

is authorized to ship because an issue cannot be re-

solved at the supplier site. Corrective Action Holds

are also automatically placed on any Inspection Or-

der for parts that have pending Corrective Actions

with the supplier. The Hold can be lifted by the

buyer or quality manager to approve shipping even

though Corrective Action is still pending.

Corrective and Preventive Action

Solumina’s closed-loop Corrective and Preventive

Action (CAPA) process manages investigation, ac-

tion items and verifications. Each Corrective Action

is a project coordinated by a facilitator responsible

for following up on investigation and action items

until there is an agreement and commitment on

resolutions.

Corrective Action can be requested from either dis-

crepancies or Corrective Action Requests. Correc-

tive Action Requests are created to track process

improvement suggestions or issues like recurring

defects, or customer satisfaction concerns. Several

requests can be linked to a single Corrective Action.

The Corrective Action tracks investigation, root-

cause analysis, and resolution commitments. Ac-

tion items are routed according to the responsibility

identified. The root-cause analysis process can be

escalated according to the severity of the issue and

more participants can be added to the investigation

team from multiple disciplines.

The Corrective Action process is not complete until

implementation is verified and proven effective. So-

lumina allows scheduling of implementation veri-

fication tasks according to the commitment dates.

Containment processes are tied to the Corrective

Action until subsequent effectiveness verification

is recorded to verify the success of the prescribed

solutions.

Copyright © 2013 iBASEt. All Rights Reserved.

Solumina is an Operations Process Management (OPM) software suite that manages work and quality processes for the manufacturing and MRO (Maintenance, Repair and Overhaul) of highly engineered products. Solumina functional modules include Process Planning (CAPP), Manufacturing Execution System (MES), Quality Management System (QMS, CAPA), Supplier Quality Assurance (SQA), and Maintenance, Repair and Overhaul (MRO) in one integrated system.

Solumina is uniquely designed to manage the product life cycle, beginning with product and process quality speci-fications into the supply chain, continuing with the manufacture of component parts, the assembly of product, and the aftermarket service of each product unit until retirement.

Solumina functional modules include:

• Solumina Operations Process Management for Manufacturing• Manufacturing Execution System• Quality Assurance System (QA, Discrepancies, CAPA)

• Solumina Operations Process Management for Maintenance, Repair and Overhaul• Maintenance Requirements Planning• Maintenance Task Planning• Maintenance Online Execution, Non-routine Execution

• Solumina Supplier Quality Assurance• Supplier Inspection Planning• Receiving and Source Inspection• Discrepancy Reporting and Corrective Actions

More papers and resources available for download at the Library section of our website: www.solumina.com.

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