Rapid New Process Introduction (NPI), Highest quality standards following our robust Quality Management System (QMS), Meeting on-time delivery through our standardized processes removing redundancy in efforts
When reviewing customer requirements, we will dive into the full scope. What are the current needs, what are the production volumes, is this a rapid turn-around part, is the project a part family – can we group other parts in to drive down production/tooling cost, all while reviewing customer specifications/drawings/models, etc. All incoming RFQ’s are also reviewed to ensure we have the ability to effectively manufacture the requirements, AND inspect all features associated with it.
We review parts to determine how they fit within our area of core competencies. If there are minor changes in design which would allow us to be more price/lead time competitive, we will provide that feedback – along with red flags in the inspection process. The feedback doesn’t end at detail features, there are often times where introducing other details as part of a package to absorb tooling/setup costs across multiple parts is more beneficial to us and the customer.
During contract review, we verify all part/drawing numbers, revision levels, quantities, prices and lead times on the PO match the quotation. Any deviation from the quote to PO are subject to price/lead time modifications. Revisions to the purchase order while work in process is handled on a case-by-case basis, if details in production are able to be modified to the updated revision, we will work with the customer to find a mutually beneifical solution. In some cases we may ammend the PO to reflect the updated price/lead time, in other instances we may issue a separate quotation for the re-work, and re-work the affected parts currently in progress. All changes are documented in our file management, in which only the current revision of customer requirments are actively stored, all obselete data is stored in archive to maintain production history in event of recall.
Material planning is according to customer requriements, due to the nature of our business, we are unable to keep ALL material on the shelf. We work with NADCAP approved vendors for materials, and source DFARs compliant materials as required for production, with Material Test Reports (MTR’s) able to be furnished to the customer if required. Programming follows a standardized approach, with emphasis on standardized workholding, tool holding, and tooling. This stream lines our process, and enables the rapid NPI process as mentioned prior. Programs are stored by part number and revision level to eliminate risk of counterfeit part production. Scheduling follows FIFO (First In First Out), unless the customer requests expedited service. Job travelers are generated for all orders, with each step being signed as completed, with all stages affecting detail features requiring inspection.
Work orders are controlled and communicated via a job status board, where we track due dates, critical paths, and any scheduling conflicts. Updates are made daily to the status board to ensure prompt communication to the customer in the event of any production delays.
Inspections occur any time there is a process that impacts any dimensional requirment related to the part, including de-burr. Inspection reports are saved internally and are available to be delivered to the customer upon request, or as their requirements dictate. These reports can be delivered in the customer required format, or per AS9102. Non-conformances are reviewed as they occur, not to exceed a weekly Material Review Board (MRB) to perform Root Cause Analysis (RCA) on the non-conforming material. Corrective Actions are implemented, and depending on severity, documented. As non-conformances are a natural by-product of manufacturing, all non-conformances do not necessariy require documented corrective actions.
All parts are packaged with the highest levels of quality assurance in mind. We spend a lot of time and effort manufacturing your parts, and we want them to arrive to you in a condition that reflects that. All parts under 50 lbs are shipped via UPS/FEDEX, with appropriate padding/fill material to prevent damage in the event of mis-handling. Any parts larger than 50 lbs are shipped via freight, with very sturdy pallets/crates built to also prevent damage. All freight parts will also be sent with corrosion inhibitor (IF PERMITTED) and shrink wrapped to prevent water damage/corrosion in transit.
Either our Operations Manager, or the Quality Manager various updates on projects. Typically, if everything is on schedule, no update is needed. Buyers, supply chain managers, procurement professionals are extremely busy people as well. We don’t aim to over-load their inboxes with updates, but can adjust as required. In the event a customer requires periodic updates through the process, those updates would be provided by our Ops Manager.
MTR, OmniMAX Certificate of Conformance (CoC), NDT inspection reports, OmniMAX Dimensional Inspection Reports (DIR), AS9102 Form 3 (FAI Report), PPAP Documentaion, frozen process documentation. All records are maintained for a minimum period of 10 years, or longer as required by the customer. Additional documentation/project definition may be provided as required by the customer.
All Digital Product Definition (DPD) is stored within OmniMAX, and not disseminated to any outside vendors without verification of conformance to the customer/federal requirements. Only ITAR compliant personnel are permitted inside the facility, and all visitors must sign in and if required, be escorted while on the premises.
Typical quote response time is <24 hrs, again, we are a rapid JIT manufacturer. However, some lead times can vary depending on complexity/volume of RFQ. If more time is required, it will be communicated to the customer within the 24 hour window.
Expedited orders are our greatest strength. All expedited requests are reviewed prior to quote submission to determine tooling/material inventory or avaialability. We believe the most effective way to complete expedited requests on time is through the highest levels of teamwork. If we don’t have the tooling or material, we will provide alternatives that may still meet your design intent, while allowing us to also meet your timeline requirements. All expedite orders are subject to an expedite fee.
Quality issues will be directed to our Quality Manager. Production/delivery issues will be routed to our Operations Manager. In the event of non-conforming escapement to the customer, we will review the non-conformance directly with the customer, complete Root Cause Analysis (RCA) through the 5-why’s process, and delivery a Non-Conformance Corrective Action (NCA).
Reach out! Ask the question, if we can’t be the answer, we know somebody that can, and we will happily point you that direction!
