Quality Overview. This is a photographic template your photograph should fit precisely within this rectangle.

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1 This is a photographic template your photograph should fit precisely within this rectangle. Quality Overview 2008 Eaton Corporation. All rights reserved.

2 Quality Quotes Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives. Quality is not an act it is a habit William A Foster Quality means doing it right when no one is looking Henry Ford Quality in a product or service is not what the supplier puts in. It is what the customer gets out and is willing to pay for Peter F Drucker Quality is never an accident; it is always the result of intelligent effort John Ruskin

3 Eaton as One Company The goal of EBS is to drive performance excellence through the deployment of company-wide values, tools and practices, thereby enabling Eaton to become a premier diversified industrial enterprise.

4 Our Vision To Be The Most Admired Company In Our Markets. To be measured by what: Customers say: We want to do more business with Eaton Shareholders say: Eaton is one of my best investments Employees say: I am proud to be part of the Eaton team

5 Our Mission To be our customer s best supplier, providing distinctive and highly valued products, services and solutions.

6 Eaton s quality policy It is the policy of the company to provide products and services that meet or exceed customer expectations and satisfy them by anticipating their needs and requirements. We set and review objectives and continually improve the effectiveness of the Quality Management System Eaton Corporation. All rights reserved. 6 6

7 Excellence in quality Deliver a premier quality experience to our customers and simultaneously achieve best in class total cost of quality. To achieve this: New products hit the market with higher reliability than current products. New processes launch with higher first pass yields than current processes. Incoming supplier quality is at least equivalent to Eaton outgoing quality. Everyone contributes to proper execution of manufacturing process controls Eaton Corporation. All rights reserved. 7 7

8 Eaton Business System EBS is a powerful integration of proven tools, processes and practices that gives Eaton a significant advantage when deployed as prescribed across the organization.

9 What is the Eaton quality system? Eaton Quality System (EQS) represents tools and processes to identify and resolve potential nonconformances. EQS is based upon the requirements of an ISO 9001 Quality Management System. EQS requires interaction between all functions because the 16 policies affect all of them. The objective of EQS is to identify and implement best practices and lessons learned throughout or global businesses. Management Responsibility Resource Management Product Realization Measurement Analysis and Improvement EQS Policy Management Review Process Quality Training Change Control Process Processes to ID Special Characteristics Eaton Internal Supplier PPAP/FAI Supplier Quality Management Process Potential Failure Mode & Effects Analysis Process Control Plans Measurement System Analysis Fresh Eyes Audit Common Manufacturing & Special Process Audit Process Capability Methods & Requirements Control of Nonconforming Material Performance Analysis & Improvement Process Corrective & Preventive Action Policy Quality Alert System 2008 Eaton Corporation. All rights reserved. 9 9

10 Quality Concepts Definitions Importance of Quality Corrective Preventive Actions Continuous Improvement Concepts

11 What is Quality? The total combination of features, characteristics, and services (marketing, engineering, manufacture and support) through which the product or service in use will meet the expectations of the customer (internal or external).

12 What is an Audit/Assessment? A quality audit is an independent (unbiased) review of performance against some standard of acceptance. Internal Audits DNV third party audit

13 Why is Quality Important to Me? Quality makes our business more competitive which benefits all of us. Quality brings profit to the bottom line through customer satisfaction, customer retention and greater capacity for work. Over time, in a free market, better quality commands a higher price for our products and services. When customers have options, they reward quality and punish laggard organizations, both in the marketplace and in the stock market.

14 What is the Difference Between Corrective and Preventive Actions? Effort on correction of a situation is always after an incident has occurred. Corrective actions are many times expensive and at times are not reliable in stopping the problem. Preventive actions anticipate what could go wrong and resources are assigned to prevent the difficulty before it occurs.

15 Corrective and Preventive Actions Concepts Identify Potential Non- Conformities: FMEA, Customer Complaints, Process Capability data, Internal Audit Concerns, Management Review findings, others. Corrective and Preventive Actions should follow a structured problem solving methodology (8D based) Corrective Action Initiate Structured Problem Solving: When corrective action specified by the customer When non-conformity can have significant impact on safety, quality of efficiency At the site s discretion Ongoing tracking of open issues Management Review: effectiveness of process

16 Corrective Action Processes (8D) are somewhat similar to Continuous Improvement Processes Some Eaton Continuous Improvement methods are: Eaton Lean System Six Sigma PROLaunch Six Sigma for Design & Development (SSDD)

17 Growth & Operational Growth & Operational Excellence Excellence Eaton Value Cycle Corporate Accounts PROLaunch Eaton Lean Six Sigma Eaton Quality System Supply Chain Management Fixed Capital Optimization We have identified and will continue to identify tools that, when rigorously applied across all our businesses, can make us the best, most profitable operating company in the world.

18 8D Problem Solving Problem Solving Approach 8 Steps Brainstorming Pareto Diagrams Five Whys Plan Do Check Act

19 One Page 8D Report Step 2 Problem Definition Who: What: When: Where: How: How many: Picture Step 1 Team: Supervisor: Plant: Engineer: Date: Quality: Team Leader: Technician: Step 3 Containment Continuous Action Operator: Operator: Operator: Operator: Problem Statement: 1.- Why 2.- Why 3.- Why 4.- Why Step 4 B Identify System Root Cause ( 5 Why): Step 4 A Identify Process Root Cause ( 5 Why): 1.- Why 2.- Why 3.- Why 4.- Why 5.- Why 5.- Why Root Cause Statement: Root Cause Statement: Step 5 Implement Corrective Actions Process: Step 6 Verify Solution System: Step 7 Prevent Problem Recurrence

20 Calibration Calibration is the validation of specific measurement techniques and equipment. It is the act of checking and possibly adjusting the accuracy of a measurement instrument against a known set standard (example: Caliper checked against a gage block).

21 Calibration can be called for: with a new instrument when a specified time period is elapsed when a specified usage (operating hours) has elapsed when an instrument has had a shock or vibration which potentially may have put it out of calibration whenever observations appear questionable

22 ISO & EQS Requirements Quality Management Systems call for an effective calibration system which includes formal, periodic, and documented calibration of all measuring instruments. ISO standard requires that these traceable actions are to a high level and set out how they can be quantified.

23 Calibration Traceability To improve the quality of the calibration and have the results accepted by outside organizations it is desirable for the calibration and subsequent measurements to be "traceable" to the internationally defined measurement units. Establishing traceability is accomplished by a formal comparison to a standard which is directly or indirectly related to national standards (NIST in the USA).

24 Devices that are Calibrated at Newbern Calipers PI Tapes Thickness Gauges Pressure Gauges Scales Timers Temperature Gauges/Controllers Laser Mikes Testing Equipment (Mixing & Long Length Labs) Footage Counters

25 What does this mean for me? Gauges are issued to individuals or locations in the plant and are calibrated on a defined schedule It is very important for gauges assigned to specific locations to remain at those locations so that they can be calibrated on time this is an ISO9001 and EQS requirement

26 Equipment Calibration Measurement equipment is issued out to employees and are coded with a serial number for tracking purposed in our calibration system. They are assigned a number for the purpose of traceability which is permanently attached to the gage by engraving it on the gage or attaching a permanent label. If it lost, another one must be issued. No gage is to be used unless it is engraved with the legible serial number that matches up with your name in the calibration tracking system. If the numbers are worn or break, they will be replaced by the company. If gage is lost or stolen, employee is responsible for replacement. Replacement prices OD Tapes $15.20 and Tape Measures $10.45

27 Travelers (Shop Orders) A traveler is printed for every hose that is made and stays with that hose until it is closed out and back flushed in finishing. It is very important to fill out the traveler completely and correctly. The traveler is considered to be our traceability link to every hose made. Examples: Toyota (brakes) and Firestone (tires) If you see a defect while running a pole in the process room, mark the outside of the hose with a piece of red tape, at the beginning and the end of the defect on the cover. ALL defects must be accounted for and recorded on the traveler. It will also signal the finishing operators to cut out the defect(s) before shipping to the customer.

28 Traveler (Shop Order)

29 Hose Specifications Family Group = GH493-12, H43012; FC736-12, H430R12 NEWBERN ITEM = H43012 ROUTE = ANY SPIRAL DESC =100R12 COLOR = BLACK SIZE = 3/4 PLY = 4 LENGTH = 150 REASON = LAYLINE WORDING REVDATE 8/7/13 RVN = GX EXTRUDER USE STEEL MANDRELS ONLY MANDREL SIZE = 3/4" TUBE STOCK = TUBE GAGE =.065 PIN = 50 DIE = 57 lbs./ft. =.1005 TUBE OD =.880 +/-.010 ( ) USE FC GERMAND DOUBLE RING TOOLING POLES / SET UP 25 SPEED = FT/MIN SET-UP TIME = 2.9 HRS. New 4-Spiral TAKE OFF GEARS: R = 48 N = 96 RANGE GEARS: R = 84 N = 42 Old 4-spiral/6-Spiral PIV =.974 RANGE GEARS: R = 60 N = 60 LENO F /2 x PLY WRAP lbs./ft. =.0040 CARRIERS = 2 WIDTH = BACKING R /2 x.012 lbs./ft. =.0231 GAGE = WIDTH = Using your calibration equipment, you will measure the hoses at different intervals and record information. 1ST DECK W " BPCS WIRE lbs./ft. =.1332 WIRE ENDS = 78 5 ENDS, 1 END) or (18@ 4 ends, 2@3 ends) Coverage = 89.3% PITCH = New 4-Spiral Old 4-Spiral/6-Spiral Spiral Angle1 = 52.7 SPIRAL O.D. = TO New 4-Spiral DECK GEAR: 87 Old 4-Spiral/6-Spiral DECK GEAR: 83 BACKING R /2 x.012 lbs./ft. =.0231 GAGE = WIDTH = ND DECK W " BPCS WIRE lbs./ft. =.1330 WIRE ENDS = 78 5 ENDS, 1 END) or (18@ 4 ends, 2@3 ends) Coverage = 84.5% PITCH = New 4-Spiral Old 4-Spiral/6-Spiral Spiral Angle2 = 52.7 SPIRAL O.D. = TO New 4-Spiral DECK GEAR: 92 Old 4-Spiral/6-Spiral DECK GEAR: 88 BACKING R /4 x.012 lbs./ft. =.0247 GAGE = WIDTH = RD DECK W " BPCS WIRE lbs./ft. =.1425 WIRE ENDS = 80 5 END, 2 ENDS, 1 end) or (20@4 ends) Coverage = 85.5% PITCH = New 4-Spiral Old 4-Spiral/6-Spiral Spiral Angle3 = 54.5 SPIRAL O.D. = TO New 4-Spiral DECK GEAR: 82 Old 4-Spiral/6-Spiral DECK GEAR: 87 BACKING R /4 x.012 lbs./ft. =.0247 GAGE = WIDTH = TH DECK W " BPCS WIRE lbs./ft. =.1434 WIRE ENDS = 80 5 ENDS, 2 ENDS, 1 END) or (20@4 ends) Coverage = 81.6% PITCH = New 4-Spiral Old 4-Spiral/6-Spiral Spiral Angle4 = 54.8 SPIRAL O.D. = TO New 4-Spiral DECK GEAR: 86 Old 4-Spiral/6-Spiral DECK GEAR: 91 COVER R x LAP COVER lbs./ft. =.1019 CARRIERS = 1 PITCH = GAGE = WIDTH = COVER O.D. = TO 1.210

30 Traveler (Shop Order)

31 Non-Conforming Material Rubber Manufacturing Compounds Every batch of rubber made is tested before it is released for use either to external customers (Garsite, Forest City) or our internal customer (Long Length). If a skid of rubber is needed in the Long Length Prep or Mandrel Prep areas, it cannot be moved from the mixing floor unless it has a green dot on it.

32 Non-Conforming Material All rejected material is put in its respective Quality Hold Area and each skid must have a completed HOLD Rejected Material tag attached to it! Quality and Manufacturing personnel will disposition the material on hold.