Quality Operating Systems
Customer Support Programs
ISO
A2LA
Quality
Operating Systems
In today's hyper-competitive environment, the bar only goes up. The marketplace
insists upon the very best possible quality. At Eastern Alloys, quality is a
multi-dimensional activity that cuts across all business levels. While product
quality dominates the manufacturing focus, elements of non-product quality are
also critical to the company's overall approach to continual improvement, and
equally critical to customer satisfaction.
It is inescapable; control is a direct function, or reciprocal,
of measurement. If a process or product attribute is not or cannot be measured,
it cannot be controlled. The foundation upon which 6σ improvement
strategies are based upon MAIC, or measure, analyze, control, and improve. Each
is important but together the result is a powerful improvement tool. Companies
like Motorola and General Electric are 6σ pioneers. From raw materials to
finished product, Eastern monitors all processes to improve manufacturing
performance and alloy consistency. An accurate analysis accompanies each zinc
alloy shipment guaranteeing that alloy products meet customer requirements.
Interestingly, Eastern's internal manufacturing specifications are controlled
to a level 25% more restrictive than industry requirements and our technical
staff works to make them even tighter. Control charts verify consistency of
alloying constituents. Contaminants are closely monitored insuring optimal
product purity. Process elements such as bath temperature, combustion, pouring
rate, casting speed and cooling rate are also controlled insuring total quality
performance from one heat to the next.
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Run Chart of Average Aluminum Contents in #3 Alloys1.
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Non-product quality programs include activities such as e-mail
delivery follow-up and feedback. The internal sales order and contract review
process is continually audited to insure accurate and complete fulfillment and
in 2001, Eastern launched a formal Customer Satisfaction Audit program.
Each Eastern Alloys facilities, Maybrook, NY and
Henderson, KY are ISO 9002 registered. With close order support from the
Maybrook staff, Eastern Alloys of Kentucky earned its ISO registration in
November 2000, a short 7 months after its Grand Opening. While there are many
ISO registrars, none is more thorough than UL, Eastern's Registrar. Maintenance
audits are an important part of the company's commitment to continuous
improvement. In August 1996, Eastern Alloys was awarded with American
Association of Laboratory Accreditation, or A2LA. Among analytical instruments
at Eastern Alloys are Spectro AES units and an ICP (Inductively Coupled-argon
Plasma) spectrometer. Of the two technologies, AES analysis is often preferred
because of its combination of speed and accuracy.
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Eastern's ASTM-compliant zinc casting alloy color code chart.
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John Malmgreen, Eastern's Vice President of Manufacturing, is an
active member of ASTM (American Society for Testing Materials). He is the
chairman of two B02 Committees and an active member of the E01 committee.
Recently, John chaired the task group leading to approval of the uniform color
code system for zinc casting alloys (ASTM B908) and more recently, helped to
establish a similar code for zinc steel-coating alloys (ASTM B914). In
addition, he serves as the U.S. representative for two ISO technical
subcommittees.
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Customer Support Programs.
At Eastern Alloys, quality assurance is a systems wide,
cross-functional process. Every team member is involved to improve every aspect
of the company's business model. The goal is 100% customer satisfaction. The
company routinely checks customer (alloy) samples often preventing minor
problems from becoming more serious. Contaminants, if undetected, can
negatively affect end product performance. Elements such as lead, tin, and
cadmium can be particularly harmful. With increasingly high warranty costs and
the possibility of a product liability event, customers cannot be too careful
to insure alloy chemistry. Eastern frequently collaborates with customers on
long-term statistical (SPC) evaluation to measure, control, and improve certain
specific casting variables to improve consistency, productivity, product
quality, and cost. In-plant customer audits often result in immediate gains.
For more information about Eastern Alloys' comprehensive improvement,
engineering activities click here.
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ISO
ISO 9002 Certificate for Maybrook, NY and Henderson, KY
Click here
to see a printer-friendly version of the certificate.
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A2LA
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Kevin Faith, Lab Technician, prepares
a sample for the optical emission spectrometer.
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Eastern Alloys is proud to announce the accreditation of its
laboratory by the American Association for Laboratory Accreditation (A2LA). The
accreditation recognizes Eastern's successful completion of the A2LA evaluation
process and its technical competence in the field of chemical analysis testing.
Eastern's technicians computerize all lab data and produce analytical reports
and statistical analysis quickly and easily for customer requirements.
A2LA is a nonprofit, scientific membership organization dedicated to formal
recognition of testing laboratories which have achieved a demonstrated level of
competence. A2LA, acting as a third party assessor, accredits labs using
criteria found in ISO/IEC Guide 17025, "General Requirements for the Competence
of Calibration and Testing Laboratories."
A2LA Accreditation Certificate.
Click here
to see a printer-friendly version of the accreditation and scope.
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1. Average monthly contents of Aluminum
in #3 Alloys over the fiscal year of 2002.
Eastern Alloys, Inc. is a member of the London Metal Exchange, or
LME, ILZRO, Interzinc, NADCA, and DDC