Stork Fokker Netherlands- Brochure

Case Study: bizzApps Enterprise Quality Management at Stork Fokker Stork Fokker wanted to improve the visibility and accessibility of quality management data while reducing reliance on paper-based quality management processes. The Client Originally founded in 1919, Stork Fokker specializes in the design, development and production of advanced structures and electrical systems for the aviation and aerospace industry, and supplies integrated knowledge-based services to aircraft manufacturers, owners and operators. Stork Fokker aims to be the partner of choice for the design, development and production of leading edge structures, systems and wiring for the aerospace and defense industry. The company prides itself on being the best-in-class specialist offering smart innovative solutions at competitive prices through advanced technologies, process excellence and lean automated manufacturing. Stork Fokker achieved a turnover of €549 million in 2006 with 3,532 employees out of the total Stork Holding turnover of € 2.009 billion. The Challenge As a designer and developer of advanced structures and electrical systems for the aerospace and defense industry, Stork Fokker provides critical components to many leading European and American manufacturers of commercial and defense aircraft, missile and space systems. Maintaining the extremely high levels of quality required to ensure the integrity of these critical components requires an enormous amount of documentation. Not only does every raw material and individual component need to be perfect, but the finished hardware also needs to be fully tested and assured. Whenever a deviation or Non Conformance (NC) occurs during the production process, Stork Fokker must identify, evaluate, segregate and disposition the NC while tracking and documenting the process that results in the Corrective and Preventive Action (CAPA). The documentation of each NC requires on average 20 different documents, from drawings to structural calculations and must include evidence of the corrective actions taken. The biggest challenge facing Stork Fokker was that its reliance on a paper-based system for the recording, distribution and retrieval of this information was extremely inefficient, both in terms of the manual-based processes and the management of the data itself. Stork Fokker conservatively estimated that the management of quality related data and processes represented an annual cost to the company of over $6 million per year. “bizzApps delivered a sophisticated NC and CAPA solution that allows us to access data and manage our processes across the enterprise,” said Ton van de Minkelis, Quality Director at Stork Fokker. The Solution Stork Fokker decided to improve its systems for managing and storing the terabytes of information produced by NC and CAPA processes by replacing the existing paper-based system with one that would improve the process of monitoring, recording and managing quality data. Stork Fokker also wanted to extend the depth of quality data recorded - the existing system only recorded summaries of quality data in Microsoft Access. Stork Fokker evaluated a number of approaches to the problem and reviewed solutions from a range of different providers. Ultimately, Stork Fokker selected bizzApps Non Conformance Management (NCM) solution because it provided a very strong web-based paperless process combined with Business Process Modeling capabilities, which would enable actual processes to be improved thereby reducing the overall incidence of NCs. bizzApps’ NCM solution provides a comprehensive set of web-based tools that ensure NCs are quickly identified, tracked and fully documented. By fully integrating with the Baan ERP, NCM is able to deliver an enterprise-wide approach to quality management, bringing all quality processes and data into a single system, including those from Stork Fokker’s manufacturing locations in Papendrecht and Hoogeveen. The Benefits One of the key benefits has been the ability to view and manage quality management as an enterprise-wide system. This has lessened the burden of data management and storage related tasks while improving the overall efficiency of process. By integrating fully with the Baan ERP, NCM is able to cross-reference the status of individual NCs within each of the production orders that make up a complete sales order. The complexity of individual sales orders means that each piece of hardware often consists of many different subassemblies, each of which consists of multiple components created from a diverse range of raw materials. With the old paper-based system, tracking and tracing every NC in an order that might involve hundreds of production orders was a highly complex task and could result in hardware with NC’s being delivered to customers. The new system requires that every single aspect of an entire sales order is NC-free before it can be released as a sales order to the customer, completely removing the potential for incomplete orders to reach customers. As an entirely paperless process, NCM saves Stork Fokker engineers a great deal of time when individually detailing and documenting hundreds of deviations on a daily basis. Engineers no longer have to ask different engineering departments for an explanation of an individual NC, while there is no longer the danger of paperwork going missing because documents can be accessed online through a safe and secure system. By delivering an integrated enterprise-wide system, NCM provides access to precise quality management information through customizable and flexible measurement and reporting tools that report on both numbers and types of NCs as well as their cost to the organization. With improved access to and control over quality management information and data, Stork Fokker is now able to limit the costs associated with NC events, ultimately saving the organization around $500,000 per year. about bizzApps bizzApps delivers the most comprehensive suite of enterprise quality management solutions available to manufacturing and industrial companies. bizzApps’ provides integrated software solutions that address all aspects of enterprise quality management, from non-conformance management to supplier management, inspection management and LIMS. bizzApps’ solutions are highly process-centric solution and can be adapted to the very specific quality management needs of any company, whether in the discrete manufacturing or the process manufacturing sector. Headquartered in The Netherlands, bizzApps combines over 20 years of industry expertise with a strong customer commitment to deliver business value to over 100 customers worldwide. For more information on our solutions, please contact us or visit: www.bizzapps.com