PLASTICS-USA

1. PLASTICS-USA PHASE IV: Model System for ISO Implementation Project: ISO Implementation at Plastics, USA December 14, 1999

2. Team ISO Implementation Plastics USA • Glenn Gee ggee@abcs.com - Project Liaison • Cathy Petretich catherine.petretich@worldnett.att.net - Team Facilitator • Team Members • Terry Bilke bilke@execpc.com • Perry Goss tcsi@murlin.com • Alan Stolzer stolzeraj@slu.edu

3. Introduction Company Background Project Update Project Plan Progress Model System for Implementation Incorporating Team philosophy Data and sampling plan Financial aspects of ISO 9000 Documentation assessment Team Course Evaluation Works Cited Appendix A Appendix B Appendix C Appendix D Contents Plastics USA

4. Introduction Plastics USA Project: To help Plastics USA, a small plastics injection molding company, to implement an ISO 9001 based quality system. • Team will develop model system for ISO implementation Phase IV describes findings and recommendations

5. Company Background Plastics USA • Located northeast of Terre Haute, IN • 80 full-time workers • 3 shift operation • Seeks various products to design and produce • Company unsuccessfully attempted registration once before • Lack of commitment from management • Inadequately trained ISO 9000 rep • Quality manual and procedures in place • Quality manager is working diligently to meet timeline

6. Project Update Plastics USA • Plastics USA is assessed as follows: • Motivation of company – medium strength • Information and education – low (training) • Resources involved – low, insufficient • Planning for registration – high • With the possible startup of internal audits, it is possible that top management will provide more support in the effort.

7. Project Plan Progress Plastics USA • Target for registration is 4/1/00 • Status of project steps: • Management training – retraining is planned • Develop quality manual – registrar will review in mid-January • Contract registrars – one has been selected and is now in place • Sign contract with registrar – done • Develop procedures – ongoing • Write work instructions -- ongoing

8. Project Plan Progress Plastics USA • D-day – (start up of system) – delayed 1 month • Internal auditor training – has been accomplished • Workforce training – memos and briefings done • Start internal audits – to begin in mid-December • ISO 9000 Network audit –scheduled for late Jan • Management reviews/Pre-assessment by registrar/Assessment by registrar – one has been prepared • Celebration of registration – will be planned

9. Role of Class Team Plastics USA • Provide support for the implementation effort • Provide toolkit ideas for quality improvements • Provide critiques for upcoming systems procedures that are being developed • Provide critiques for upcoming work instructions that are being developed • Provide ideas for possible forms as requested by the company • Other tasks or duties as assigned

10. Model System for Improvement Plastics USA Four areas were deemed most critical: • Incorporating team philosophy • Best uses of data/statistical methods • Financial aspects of ISO 9000 certification • Documentation Assessment

11. Team Course Evaluation Plastics USA • Evaluation is vital to the success of a team • The team has been strengthened by the evaluation process employed • Team members are evaluated on a weekly basis on participation, timeliness, and content • An analysis of weekly evaluations indicates that the team is functioning at a high level, and has shown consistent improvement (see chart on next slide) • Lessons learned have been documented

12. Works Cited Plastics USA Bubshait, A. & Farooq, G. (1999). Team building and project success. Cost Engineering. Crosby, P. B. (1980). Quality is Free. New York: Penguin Group. Chapters 1-3 DeVor, R.E, Chang, T., and Sutherland, J., Statistical Quality Design and Control, Macmillan, New York, 1992. Edmunds, T. (1996). “Smooth Out the Road to ISO 9000 Implementation”, Quality Magazine. Grant, E.L., and Leavenworth, R.S., Statistical Quality Control, 6th ed., McGraw Hill, New York, 1988.

13. Plastics USA Lamprecht, J. (1992). ISO 9000. New York, NY: Marcel Dekker, Inc. McTeer, M., & Dale, B. (1995). “How to achieve ISO 9000 series registration: A model for small companies.” Quality Management Journal 3 (1), 43-55. McVinney, C. (1993). http://www.michaelsmcvinney.com/articles/sixteen_ways.htm) Singhal, V. & Hendrinks, K. The Financial Justification of TQM. Center for Quality Management Journal Sinn, J. Disciplined culture for change: conducting and managing projects. Toolkit B.

14. Plastics USA SPC and Injection Molding. http://www.ramat-negev.org.il/~howarda/SPC.HTM Stein, S. (1999). “A Recipe for Well-Done Procedures”, Quality Progress. Summers, D. (1997). The Costs of Quality. Quality. Upper Saddle River, NJ: Prentice Hall Tips for ISO 9000 Preparation: Control Nonconforming Product. Quality Magazine, September 1999. http://qualitymag.com/articles/1999/sep99/0999f4.html Rohladner, D. (1999). Effective team building. IIE Solutions.

15. Appendices Plastics USA • Appendix A • Appendix B • Appendix C • Appendix D

16. PLASTICS-USA PHASE IV: Model System for ISO Implementation Project: ISO Implementation at Plastics, USA December 14, 1999