Implementation of ISO 9001:2000
The ISO 9001:2000 Quality Management System contains the components required to document every step of the production process, allowing for better control, from approving vendors to shipping finished product. Good components make a better product. Take, for example, the approved vendor list. Being on the approved vendor list means the company has supplied reliable components for a specified number of shipments. Without proper documentation, components could have been purchased from an unsatisfactory vendor a second time.
In addition, proper documentation of processes ensures the control necessary to produce quality products. Step by step standard operating procedures ensure the process is performed the same way each and every time. Detailed documentation denotes where process revisions are needed for a step clarification, further operator training or where a particular step in the process simply isn't working. Deviations are recorded and maintained for analysis in recognizing these needs. Through the ISO 9001:2000 Quality Management System, everyone within Catalyst Microtech, from the President to the newest employee, works to achieve the highest possible quality.
Employee Training
Employee training focuses on a process being performed the same way each and every time so there is no difference between the first shift operator and the third shift operator. All employees attend an orientation and training session that determines their initial skill level. Operators attain skill certification through a two-part test consisting of a written exam and a hands-on skill evaluation of the process. After an operator becomes proficient at their current skill level, more complex tasks are incorporated. The operator is tested and, if passing, acquires the next skill level. Periodic re-testing and auditing of the operator's skills ensure that the process does not change.
Communication is the cornerstone of the Training foundation. The ability to communicate effectively determines whether work instructions are imparted clearly and concisely. During training, operators are encouraged to ask as many questions as necessary for clarification of work instructions. However, if the same questions are being asked every time, either the work instructions are ambiguous and clarification is needed in the operating procedure or the operator needs to be re-trained.
Cross-training, another important facet, avoids downtime because an employee has been limited to performing a single process. All operators attain the basic skill levels required to perform several processes. When proficient, operators receive the two-part exam and the hands-on skill evaluation for the additional processes.
Online SPC
Statistical Process Control (SPC) - Statistical analysis using a predetermined set of control limits to identify and correct variations in a process. Charts and graphs incorporating these predetermined control limits depict process variations.
For current SPC data on your product, log into the Customer Center and get the information you want, when you want it.
Customer Feedback
We always love to hear from satisfied customers but we need to hear about any dissatisfaction you might have as well. We want to do everything within our power to build you the best possible product and we need your help improving our service. Tell us how we're doing.
Process Flow
Process Flow establishes the movement of product through the production area from process step to process step. Catalyst Microtech's engineers work in conjunction with customers to meet their individual production requirements before any product ever reaches the production area. Process flow ensures customer specifications are met during the build so that processes aren't left out or added unnecessarily.
One stage of the process flow for high volume production is 'Send Ahead Parts.' 'Send Ahead Parts' are a small quantity of parts processed from start to finish and shipped to the customer ahead of time to qualify a process before that process is committed and high volume assembly begins.
In addition, Acceptable Quality Level (AQL) inspections are performed after die attach and at pre-seal inspection. The AQL is the allowable number of defectives in a sample size considered acceptable. We've adopted the MIL- STD 105E Level II - Normal Inspection as our formal AQL system.
Quality Control Plan
Our engineering department developed a default Quality Control Plan which can be customized to meet specific customer/device requirements. The Quality Control Plan determines the evaluation method, sample size, frequency of sampling and the method employed to control the process. Evaluation methods differ from process to process and range from a Go/No Go Gauge to a measurement station. Build lots are sampled in accordance with MIL-STD 105E. Sampling frequencies are based on SPC limits and can be adjusted to more, or fewer, samplings with regard to historical data. Whether it's an X-Bar/R Chart or a Pass/Fail Log, all data is recorded and analyzed to better provide our customers with information needed to identify specific areas for improvement. The Engineering Department would like to talk to you about your customized Quality Control Plan.