RONAL TOOL : EDM TOOLROOM
QUALITY CONTROL MANUAL
The quality control system at Ronal Tool is designed to provide us with a method for carrying out quality control procedures; which enables us to treat all jobs uniformly in our shop environment.
Process Sheets:
Every job has four electronic pages tracking it through to completion: the Quote Page, generated from the quote database, the Shop Order Page, generated from the inventory database, the Packing List, generated from the inventory database, and the Invoice, generated from the inventory database. All of these sheets are interactive and the information contained on each is compiled in our Relational Databases.
1. The Quote database establishes all job information. This database sets the ground work for each job and contains the following information: customer, contact person, date quote was received, date quote is sent to customer, delivery date, customer's inquiry number, part number, drawing revision, part name, quantity required, material with cost and source, outside services and cost, mill hours, turn hours, grind hours, wire hours, sink hours, misc hours, inspect hours, total hours, hourly rate, total labor cost, price each, extended price, a comment field, shop order number, purchase order number, job status, and a quality control field. This database generates the quote sheet, which is sent to the customer and can be used as the basis for their purchase order.
The quote sheet/page contains the following information: customer, contact person, customer's inquiry number, part number and name, quantity required, material with cost and source, outside services and cost, price and expected delivery of finished product. This sheet/page is sent to the customer, electronically or physically, and can be used as the basis for their purchase order.
2. The inventory database is related to the quote database. All information from the quote database is drained into the inventory database when a job is entered into production. In addition to all the fields from the quote database, the inventory database contains the following fields: freight, invoice total, invoice number, invoice date, shipping carrier, actual mill hours, actual mill hours cost, actual turn hours, actual turn hours cost, actual grind hours, actual grind hours cost, actual wire hours, actual wire hours cost, actual sink hours, actual sink hour cost, actual misc hours, actual misc hours cost, actual inspect hours, actual inspect hours cost, actual total hours, actual total hours cost, total labor cost, total material cost, total outside service cost, overhead figure, overhead cost, total overall cost, and profit or loss.
The actual hour fields, and the actual hour cost fields are generated from the related Time Card Entry database and the Employee database.
The Inventory database produces the shop order sheet/page.
The shop order sheet/page identifies work in progress and is the connection to each customer's purchase order. Each shop order is assigned a unique number and is divided into four parts: header, material/outside services, work center and quality control.
The header records the shop order number, customer's name and purchase order number, the part number and name, revision level, quantity ordered and date job is to be delivered.
Materials and outside services are detailed in the following section. Included is the beginning geometry of the material along with the grade, name and supplier, dates order was placed and receipt of material. All outside services are logged and tracked in the same manner. This area is used to note any special instructions pertinent to the job.
The work center is used to record the operations performed such as mill, lathe, grind, wire, sink, and miscellaneous time. Each operation has a column where employees can list their ID, date and number of hours worked.
The final section of this sheet establishes the quality control level required for the job. Inspection levels range from 0, meaning no inspection required, to 3, the most detailed inspection. A separate inspection report is used to record print dimensions and tolerances and then show the actual dimensions of the part. Finally, the job is dated when work is completed and signed by the foreman when approved for shipment.
3. Two copies of the Packing List accompanies the finished product to our customer. It includes not only information about the item itself, but also customer information including the person who is to receive the shipment. The customer is asked to sign the Packing List as proof of receipt. One copy is left with the part for our customer's records and the other copy is returned to our office to begin the billing process.
4. Our Invoice is generated through the information contained on the previous sheets plus the customer's purchase order.
Control Systems:
1. Communication:
Communication is the hallmark of our control system. Communication is the first step in problem resolution and implementation of our quality control procedure. Defining what our customer wants and deciding how we can meet those needs is accomplished through clear and concise communication. Ronal Tool's commitment to communication will insure every job meets the customer's requirements.
