When dealing with a single-source supplier for a critical part, it is essential to address the issue of parts being rejected during receiving inspection. The material review board’s subsequent acceptance of these rejects indicates a disconnect between the inspection process and the supplier’s performance. To address this problem, the process improvement team should take the following steps:

Review the Specification Limits with Engineering: The team should collaborate with engineering to revisit the specification limits for the critical part. This involves assessing whether the existing tolerances are appropriate, considering factors such as functionality, safety, and performance. If the current specifications are too stringent or not aligned with the supplier’s capabilities, adjustments may be necessary.

Analyze the “Voice of the Customer”: Understanding customer requirements is crucial. The team should gather feedback from internal stakeholders (such as production, quality, and engineering) and external customers to identify their expectations regarding the critical part. This information will guide any necessary changes to the specifications.

Evaluate Process Flow Structures: Examine the entire process flow, from supplier to material review board. Identify bottlenecks, potential sources of defects, and areas where improvements can be made. This evaluation helps pinpoint the root causes of the rejects.

Assess Key Measures of Process Performance: Quantitative metrics related to quality, delivery, and cost are essential. The team should analyze data on defect rates, lead times, and other relevant performance indicators. This assessment provides insights into the effectiveness of the current process.

Consider Supplier Relations: The team should engage with the supplier to discuss the issues and collaborate on solutions. Open communication and a cooperative approach are essential for resolving the problem.

In summary, the initial step for the process improvement team is to review the specification limits with engineering. This ensures that the tolerances are realistic and aligned with both customer requirements and the supplier’s capabilities. Subsequent actions will involve addressing process flow, performance metrics, and supplier collaboration2.

References: 1ASQ Certified Manager of Quality/Organizational Excellence 2ASQ Guide to Process Improvement and Change