Ensuring product quality in feeder-system factory approach

Purpose of the Master's thesis is quality ensuring in the feeder-system factory approach during an off shoring project. A theoretical background gives tools and techniques to maintain quality in the feeder-system factory approach. Quality ensuring in the feeder-system factory approach was done by using metrics of defects per unit (DPU) and rework time. Control charts were constructed from defects per unit values to indicate the process status. Rework times data were used to create pare to charts to guide the company to solve problems in the priority order Before the feeder-system factory approach started the feeder factory operators were training assembling work for three-month period. Results from the rework time level verified that training period before the off shoring gave basic knowledge about assembling work of High Level Assemblies (HLAs). The most significant reworks in the system factory were made for assembles where operators had to perform special adjustments, which were missing from assembly instructions. Small manufacturing volumes and complicated electromechanical assembles have kept manufacturability in a level where operators make final adjustments based on their own knowledge. At the beginning feeder-system factory approach decreased the quality of HLAs. When the feeder factory knowledge level about special characteristics of HLAs increases, quality starts to improve. A company which is planning to initiate a feeder-system factory approach has to keep in mind that learning does not happen suddenly. In the case of HLAs it took more than one year to reach approximately the same quality level as before the feeder-system factory approach