Improving Collins Aerospace's Quality Clinics to Meet Quality Clinic System Certification Requirements

Abstract

Collins Aerospace, a leader in aerospace technology, serves six key sectors, including aviation, defense, and space. With 2.5 million components operating daily, the company prioritizes safety and quality through its Quality Clinic System, designed to identify and eliminate defects. This system enforces compliance with seven elements: People, Performance Metrics, Location/Layout and Flow, Gauging and Equipment, Triage and Containment, Visual Management, and Performance Review. At the Santa Isabel site, comprising four production buildings, compliance with the Quality Clinic Certification stood at 72%. To address this, a DMAIC project was launched to achieve 100% compliance, targeting a 20% reduction in Scrap, Rework, and Repair (SRR) costs and improved customer satisfaction within six months. The project followed a structured approach: defining goals, measuring current compliance, analyzing deficiencies, implementing solutions, and establishing controls for sustainability. Data collected through a Gemba Walk revealed areas needing improvement, particularly in five elements. Root cause analysis and a cost-benefit evaluation guided the development of practical solutions. Long-term controls, including compliance audits and updated process flows, were implemented to ensure sustained progress. The project successfully increased compliance to 100%, reduced SRR expenses by 20%, and enhanced customer satisfaction. These outcomes underscore Collins Aerospace's commitment to quality and operational excellence.