January 13, 2009
Achieving ISO/QS 9000 Certification
"A variety of reports can be generated to substantiate that one indeed 'one says what one does' and 'does what one says", said, Ed Johnson, CMMS Manager, WCI Steel, Inc.
Several years ago, the ISO standards were revised to require the use of computerized maintenance management systems (CMMS) in place of the archaic and the error-prone manual method. WCI Steel, Inc. in Warren Ohio has been quite successful in attaining and maintaining their ISO Certification with the aid of MAPCON, a powerful CMMS.
This case study briefly examines WCI Steel Inc.'s success with MAPCON.
Say what you do: Documentation of SOPs
MAPCON® provides an excellent and easy-to-use vehicle for creating and editing the control processes for both maintenance and operations. MAPCON security provides the necessary control features for creating and editing SOPs (Standard Operating Procedures). The most up-to-date changes are then made available for on-screen viewing throughout the plant. MAPCON eliminates the need for developing procedures for handling and removing out-dated information, which is inherent in a manual system. The possibility of accessing out-dated information, a definite ISO non-compliance, is therefore eliminated. Furthermore, since not all procedures are ISO-related procedures, MAPCON allows the flagging of SOPs as either ISO or non-ISO procedures for subsequent sorting and reporting.
In order to assure that maintenance functions are performed safely, safety procedures, in some cases required by law, are defined for nearly every maintenance function. Safety maintenance procedures outline the steps for the task and are required for many ISO/QS procedures for equipment maintenance. MAPCON attaches safety procedures to equipment records, as well as to PM routines. When work orders for equipment are generated, safety procedures are also attached.
ISO/QS standards require that equipment having "a direct impact on the quality of the product" be identified. MAPCON enables the User to identify each piece of equipment as either ISO- or non-ISO critical. Along with ISO-equipment criticality, is the identification of which employees have the required skills to maintain ISO-critical equipment. MAPCON uses a series of Craft Codes that are defined in the software. MAPCON can access employee records to match the required skill with that of the employee. As employees participate in various training programs, the timecard system automatically updates employees' records to show their newly acquired skills.
Spare part inventory requirements and management is another important feature of MAPCON. It allows tracking of all essential inventory and items with long lead times so that the maintenance organization is provided with the tools to ascertain that the right parts are available when needed so that essential maintenance on critical equipment can be performed in a timely manner.
Do what you say: Adherence to SOPs
The most important feature of any CMMS is its ability to monitor and manage the preventive maintenance (PM) activities of the enterprise. All the features from equipment data entry system, to tracking of spare part inventory, to monitoring equipment criticality and employees' skills, only serve to support the PM features MAPCON. PM procedures detail the required steps as specified by the equipment manufacturer in order to maximize equipment uptime. Based on equipment usage and operating conditions, manufacturer's minimum standards should be adjusted and developed. Once established, MAPCON tracks and sets all due dates for various PM steps. PM work orders are generated and assigned to the appropriate personnel according to their skills determined by the required craft codes. As the downtime decreases, the overall cost decreases and quality and productivity increase.
Documentation
MAPCON, through a complete system of reports, documents all aspects of the process to satisfy adherence and compliance with the standards. A variety of reports can be generated to substantiate that one indeed "says what one does" and "does what one says."
Source: Johnson, E., CMMS Manager, WCI Steel, Inc. in a report: ISO/QS 9000 Documentation via MAPCON