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This January Company M took ISO9002:
1994 certification. The company makes small metal parts with about
thirty employees. In March a management representative of the company
phoned me that the company would like to change to a lean ISO9000
system from the present heavy documentation system. The present system
has made with advices from an ISO9000 consultant.
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Checking the present heavy documents, I asked, " Why did
you made such documents? ". Then the management representative answered
that the consultant forced them to make such documents as indispensable
to respond to ISO9002 requirements. But I found that there are no such
requirements (shalls) in ISO9002. This is a typical example that ignorance
of " shalls" tends to make heavy and wasteful documentations.
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It is my first experience to advice to make a lean ISO9000
system for a company, which has certification. Therefore I can see the
heavy documentation at hand.
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I found my lean system (called Six zero system) would
work for the system as follows.
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1. No independent management procedures
The company has twenty-three independent management procedures and
I will absorb them into a single manual.
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2. No documents numbers
The company has scores of documents and they have documents numbers
with several digits. I will delete them.
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3. No lists for control of distributions of documents
Quality manual has been distributed to sixteen sections, but I found
only one quality manual was enough in such a small company.
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4. No column for revision history in each page in Quality
manual
At present there are columns in each page and I will delete them.
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5. No QC process chart
There are about thirty QC process charts. I will change them into quality
plans with three pages.
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6. No large quality assurance chart
Now the chart is very large size and so many small letters are written
that I cannot read well. I will summarize it in small chart.
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