Inside ICI Kovatch Casting


K


Process Control Standards Survey Testimonials


ovatch Casting has a long standing history of supplying high quality


investment castings to the aerospace, military, commercial and medical industries. We are always looking to improve our operation and processes. Cost of nonconforming castings have long been measured as we continue the process to improve our processes and casting capabilities. The goal is to continually reduce the manufacture of nonconforming products. Kovatch completed two self-audits


and was the first beta test site for the ICI Process Control Survey (PCS) team. The guidelines established were to complete the self-audit surveys as unbiased as possible regarding the areas of responsibilities and disciplines. We also


had the opportunity to have the 5 ICI PCS committee members visit Kovatch and complete the PCS for


the wax


and shell departments. This in-house survey brought to light missing details within work instructions, application and training.


KCI has determined


to utilize the Survey checklists as a baseline for actions recognized as needing improvements. KCI formed a team to comply with the ICI PCS. The team consisted of representatives of the following departments: Management: Company President Manufacturing: Plant Manager Engineering: Engineering Manager Process Engineering: Process Engineer Quality: Quality Manager


The team’s goal is to become


100% compliant to the PCS areas that we determine to be applicable by 12/31/2020.


In conjunction with this, KCI found


Quality Products. Lasting Performance.


the concept of the PCS to be such that we have determined to utilize it as part of our AS9100 QMS requirements.


Bescast I


Specifically, Paragraph 4.4 speaks to requirements regarding the Quality Management System and its Processes. The origin of this requirement was the AS9100 Rev. C of the standard. At that time, KCI selected a number of processes to


satisfy the requirement. However,


considering the intent and direction of the ICI PCS, we’ve determined it makes good business sense for us to model our AS9100 QMS Processes to mirror those of the ICI PCS. AS9100 Rev. D Paragraph 4.4.1 states: The organization shall establish, implement, maintain and continually improve a quality management system including the processes needed and their interactions, in accordance with the requirements of this international standard.


When one considers the goal of the ICI PCS and the mandates of the AS9100 requirements, it’s a perfect fit for AS9100 compliance and Continuous Improvement of the Investment Casting Process at KCI in concert with the ICI Process Control Certification.


n July of 2020, Bescast conducted a self-survey, beta-audit using the new Process Audit Checklist created by the PCS Committee at the Investment Casting Institute. We split the five areas across three


people; each area required about 6-8 hours to complete. The common observation of the


+1 800-756-8794 seleeac.com


12 ❘ August 2020 ®


auditors, who were the actual owners of the areas, was the overwhelming realization of the number of legitimate deficiencies that existed, hidden by the day-to-day goals of meeting production demands.


“When we studied the


questions and looked closely, it was eye- opening to see the number of zeros, let’s call them opportunities, there were in


Ed Self, President BESCAST


areas that seemed just fine”. The questions and rating scale descriptions were crafted effectively; there was very little “gray-zone” that would result in debate about the rankings.


The checklist designers


certainly showed a knowledge of the process and real-world experience uncommon with many generic audits. One Manager commented that he


was surprised by his assumptions and was grateful to see an industry-specific checklist that had everyone excited and motivated to improve.


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