How to simplify your ISO 9001:2015 system at production?

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Table of contents

    How did you come across ISO 9001?

    • Obtaining a certificate ISO 9001:2015 or other quality system was imposed by one of your key Clients.
    • You decided to implement a quality system to standardize procedures and improve functionality as you had some organizational problems.

    Regardless of your motivation to make changes, we suspect you might feel a little bit disappointed even when you worked hard to implement the ISO 9001 system.

    • Even though many procedures were created and you agreed in writing the way they should work, it has nothing to do with practice.
    • The production hall workers spend a long time filling different orders, working cards, etc., but this paper work doesn’t translate into a real decision-making process.
    • There are many interesting rules and monitoring procedures, but only on paper, not at the production hall.
    • You are under the impression that your solutions are for your client’s monitoring requirements or for auditors, who come once a year.

    If any of the above symptoms apply to your business, check how production management software can help you.

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    1. You can get rid of binders full of product documentation and make sure your employees always have updated information.

    Thanks to the Prodio database of your products, all necessary information automatically goes from operator to production:

    1. You don’t need binders with outdated documentation because Prodio’s database of products updates automatically.

    2. You don’t have to mark and set the version of documentation – Prodio shares dates of changes and the login of a person who made them.

    3. The problem with “Knowledge management” with ISO 9001:2015 is automatically solved. However, some companies don’t know how to deal with the required norms. This problem disappears when product data is collected in real-time and subsequently analyzed thanks to employees’ comments, complaints, or remarks.

    4. The employee constantly has updated information about the product; thus, communication and information flow standards are met. In addition, thanks to production technology, a comment can be directed to a particular operator.

    Additional application of this solution:

    Influence on Clients’ image for auditors – especially in the case of big companies.

    Let’s be honest: the bigger a company is the more probability of using the “old-fashioned” ERP program. Imagine auditors’ surprise when they see computers for employees at the production hall in a small manufacturer. Prodio was often a trump card and a strong point in negotiations in automotive industry audits or other significant market players.

    A perfect place to show correction measures

    Instead of creating correction measures, especially for audits, add to Prodio updated manuals or photos of product defects and information about what should be double-checked during monitoring based on actual problems you encountered. As a result, you will improve true quality, lower the defect rate, and gain the auditor’s respect because of your right attitude to ISO 9001:2015 correction measures.

    2. You don’t have to print paper production orders and working schedules.

    One of the essential elements of all quality systems (and quite correctly, because it’s one of the main points where complaints arise) is communication between production and the office – which means giving commands.

    Practically speaking, all parameters are copied from one order to a production order and passed on to employees. Then, a catalogue with photocopies and drawings is ready to be taken to a production hall.

    Once you use production management software, such as Prodio: 

    1. You don’t have to supply any papers to the production – both order and product parameters are in the system. 

    2. The employees always know what to do – not only do they have to look into documentation, but your presence at the production hall is no longer necessary because the production plan is available online.

    3. No more lost orders and technical drawings at the production hall.

    Additional application of this solution :

    Add permanently quality control procedures and additional manuals to machines and operations on the production plan.

    Instead of putting documents that each employee should know or necessary manuals (ex. machine maintenance) at the production hall, you can permanently add them to the production plan as lines attached to particular machines or operations to eliminate paper documents.

    Lower the number of mistakes at the production hall 

    We hope that so far, you visualize how different your production could be with fewer products wasted and mistaken orders avoided once the communication between employees and information flow was working efficiently. It’s true –  and as many companies indicate, the changes are immense and effects quite spectacular.

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    3. You can finally abandon the painstaking filling of work cards and orders at the production hall and increase productivity.

    Identification and traceability (possibility of recreating working history) are the basics of quality norms. There is a necessity for registering work by employees hence the overwhelming number of notebook pages, order cards, or registers full of signatures.

    Once you use production planning software, such as Prodio:

    1. Instead of writing, it’s enough to use a key-fob and a reader, which replace a signature and employee ID.

    2. The whole working history is in the system – it’s created automatically once the active operations are registered by employees.

    3. Fast filtering and access to working history – it’s easy to find anything in the system, as the data is stored in the database, it takes only a few seconds, not hours, as before.

    4. You can control analyses and monitor efficiency in real-time – this allows you to improve production and find unprofitable orders.

    Additional application of this solution:

    Normative requirements regarding monitoring and process analyses are met automatically.

    You can quickly answer the auditor’s question about methods used for monitoring processes. With just a few clicks, you can give a satisfactory response, because you have full shop floor control.

    Improved efficiency of your team

    Using a computer or another tool that sums up real working time (not a piece of paper where anything can be written) improves work efficiency.

    4. Get rid of all forms, which got on your nerves before each audit.

    Once you use production management software, such as Prodio:

    1. Ongoing production can be marked with barcoded order cards, printed directly from Prodio – it’s enough to add such cards to each pallet or package to see clearly what they contain and who they are for.

    2. Register incompatible products and assess your team from the point of product defectiveness – in Prodio, an employee gives the number of deficiencies and reasons.

    3. You have updated order statuses and dates of confirmed lead dates – it all goes through the list of orders you use daily. Hence it’s updated.

    4. You can use Prodio’s ID as a batch number or product ID number, which you can place, ex. on the boxes or qualitative documentation.

    5. Thanks to additional boxes during work registration, you can easily register a raw material batch number used for making the product. It can be handy for automotive industry companies.

    6. The complaints are added to the list of orders – thanks to that, you avoid the necessity of creating an additional list.

    Additional application of this solution:

    Eliminate unnecessary procedures and limit documentation to a bare minimum.

    Practically speaking, the new norm ISO 9001:2015 allows for the replacement of written documents and procedures with algorithms and programs, which regulate the pace of work. In that case, is there anything better than production management software?

    Ready to Streamline Your Shop Floor?

    Online manufacturing software that puts you in control.

    Get started today

    14-day free trial - No credit card needed - Unlimited free support