Quality Management System for NCR

Quality Management System for NCR (Non-Conformance), DCR (Deviation Change Request) , Technical Queries & Audit-NCRs

technology-for-global-offshore-energy-industry

About Client

Leading provider of technology for global offshore energy industry Offers products and services for vital power and control delivery
Core Products

Subsea Production Umbilicals (SPU)

Subsea Power Cables (SPC)

Intervention Workover Control Systems (IWOCS)

Renewables (Inter array Power Cables)

Challenge

Quality Issue Management system was not scalable, long-winded and cumbersome. As a result of this employees were not raising issues on the system. There was lack of automated operational & executive reporting. The interface was not user-friendly and was prone to human errors. The process flow was complex and user did not have visibility on the critical items. Quality team could not manage multiple locations (6 global locations) due parallel processes running due to an un-usable application.

Background


Customers Quality Issue management was not able to keep up with the business growth and there were inconsistencies in data collected throughout the different locations around the world. Company was loosing money to their customers as well as suppliers. There were 35-40 Non-conformances raised in a month with 10-15 concession requests and 10-15 technical queries.

Solutions

A JAVA based application was designed with improved usability features. Manual process changed to  into electronic form for concessions & technical queries. Wizard based screens with autocomplete feature integrated with ERP ensured minimal human errors. Process was re-designed to be lean and have faster turnaround time. Improved visibility on critical & overdue issue with real time reports for shop floor users and executive dashboard for the management members. Active management through workflow and notification. Root Cause Analysis (risk assessment matrix) for each item incorporated in the process. integration with knowledge base for CAPA with separate approval process, full audit trail, a powerful search & automated PDF report generation to share with clients and suppliers.

Key Benefits

Manual process changed into electronic form for DCR and ITQ, bring in standardization and single point quality solution available 24x7 to all users in all locations.

Increase accountability through assignments, process step approvals and audit trail.

Increase in number of issues raised by 30 % in 6 month and 35 % increase in over processing per month.

Reporting capabilities helped in highlighting overdue and critical issues at the right time to the right people.

Comprehensive Root Cause Analysis (risk assessment matrix) with a knowledge base for Corrective Action Preventative Action.

Improved overall quality of product & standard documentation of all issues for all clients in all locations.

Easier compliance to international standards such as ISO.

Technology Used

JAVA, Activiti 5, MS SQL Server 2012, Apache Tomcat 7.x

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