ZenQualityQuality in any manufacturing industry is the process of selecting the right tools, systems and methodology to ensure that all the processes, parts and products meet the desired specifications at any given point of time. The objective of any quality system in the manufacturing industry is to manufacture parts and products at specified standards and quality levels, without any defects at a single go. In today's competitive world, manufacturing industries are facing numerous challenges in improving productivity and profit margins while meeting a desired level of quality, customer satisfaction, rapidly changing customer and market demands, and complying with regulatory requirements. Considering all these challenges, quality is very crucial for any manufacturing industry to minimize the repair/rework cost, customer service cost to improve profit margins and increase customer satisfaction levels. Zensar's solution is specially designed to cater to these challenges and needs of manufacturing industries. The solution comprises three separate modules that can be integrated or configured separately as per the requirements. - Supplier Quality Module
The Supplier Quality Module helps to standardize and measure quality planning methodologies, monitor suppliers performance by measuring part rejections at various levels of supply chains, delivery time, non-compliances and several others. This module includes functionalities such as supplier master data, approved vendor list, specification of parts, contract agreements, SLAs, inspection and qualification standards, sampling plans and defect definition. It also has the ability to capture data from various levels of the supply chain and extract reports as per business needs. Business Benefits: - Facilitates a better supplier management process
- Enables early detection of products assembled with defective parts reducing repair cost
- Improves productivity and product reliability as it records and measures supplier performance (PPM) enabling suppliers to take corrective and preventive actions towards improving quality of parts
- Enables supplier rating system
- Leverages data for BI analytics and supplier charge-backs
- Plant Quality Module
The Plant Quality Module enables industries to optimize the manufacturing processes to improve productivity and increase profit margins by reducing repair cost and rejection. The module comprises functionalities such as creation of product and process specifications, accepted quality level standards, workmanship standards, inspection of data sheets, sampling plans and data capture from various process, inspection, test stages and storing it in the data base. The module also includes SPC (Statistical Process Control), reports including yield report, component replacement PPM, supplier PPM, process capability and track implementation of a corrective and preventive action plan against defects, failures or non-conformances.
Business Benefits: - Reduces manufacturing cost by reducing repair cost and rejection
- Improves productivity and increases profit margins
- Captures non-conformances and tracks the implementation of corrective and preventive actions
- Facilitates operational excellence
- Provides valid informative inputs to help make decisions on manufacturing, alerts and material purges
- Customer Service Quality Module
The Customer Service Quality Module includes functionalities such as service standards, warranty specifications by customers, locations or products. Customer Service Quality Module receives inputs in the form of customer complaints, feedback, customer service level agreements, failure data, repair data, replacement of parts against warranty. The module also provides various reports such as customer service time, filed failures, dead on arrivals by locations, product and customer. This enables industries to control rejections from the customers end by focusing on failures eliminating the root causes of associated failures.
Business Benefits: - Ensures effective failure analysis
- Reduces field failures and dead on arrival instances
- Reduces customer service cost and improves profit margins
- Provides an effective means to manage customer demands
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