Illustration: measurements of a bore diameter with a tolerance of plus or minus 0.020 mm. With each operator using their own method, readings spread wide, the process capability index is 0.37 and about 124 parts in 1,000 are out of tolerance. After the process is measured and standardized, the spread narrows to 0.024 mm and the capability index reaches 1.67.
Setups vary by operator, methods drift, and results vary with them.
When that person is away or retires, first-pass yield drops and nobody can say exactly why.
Capacity feels tight, but the real bottleneck has never been measured, or it keeps moving.
Every engagement has a written scope, a fixed end and a result you can act on.
15 to 30 minutes on where the time is going and whether we can help.
A short written scope with deliverables, a price and an end date.
We watch how the work actually runs, put numbers on it, and build the standards.
What to stabilize first, what to improve next, and what to leave alone.
What you get
Every engagement ends in documents your team can pick up on Monday morning. These are samples, made for an imaginary bracket, so you can judge the standard before you call.
Setup sheet
BRK-1042 · Op 20
| First-part check | Gauge | If off |
|---|---|---|
| Ø12 H7 bore | Bore gauge | T14 wear +0.005 |
AS9102 Form 3
Characteristic accountability
| # | Requirement | Result | Tool |
|---|---|---|---|
| 1 | 170.0 ±0.2 | 170.06 | CMM |
| 2 | Ø12.000 +0.018/0 | 12.009 | Bore gauge |
| 3 | Position Ø0.10 A B | 0.046 | CMM |
| 4 | Ra 1.6 | 0.9 | Profilometer |
| 5 | Note 4, break edges | Conforms | Visual |
5 of 5 characteristics conformAccept
Capability study
Bore Ø25.000 ±0.020
Capable, running 0.0035 mm high. Centring on nominal lifts Cpk to 1.91 with no other change. Gauge R&R 8% of tolerance, so the number can be trusted.
Next review after 100 partsCapable
Sample documents for an imaginary part. Real deliverables follow your drawings, your forms and your customer's requirements.
Most shops start with process standardization. The others depend on what it finds.
Turn unstable, undocumented shop-floor execution into repeatable standards and a clear improvement roadmap.
Close the gap between design intent and production reality before a launch, a scale-up or a transfer.
Find the real constraint and what drives its variation before deciding on overtime, outsourcing or capital.
Get critical process knowledge out of people's heads and into standards that match how the work is really done.
Check that a process is stable enough to automate before the money is spent.
Some problems don't need an engagement. These have a fixed scope and most can be done from what you send us.
| Package | You send | You get |
|---|---|---|
| Setup sheets and work instructions | A phone video of the setup and any notes you have | A controlled instruction for one critical operation, with the steps that cause scrap called out |
| First article inspection package | The drawing, customer requirements and your measurements | A ballooned drawing and an AS9102-style report with characteristic, material and process accountability |
| Capability study | Measurement data for a feature or process | Cp and Cpk with a plain-language verdict and what to do about it |
| Drawing and tolerance review | Part drawings | A marked-up review of GD&T errors, ambiguity and tolerances that drive cost |
| CAD from an existing part | A sample part or its measurements | A 3D model and a toleranced drawing |
Check your own process before you talk to anyone. Every tool runs in your browser, so your data stays with you. For the method behind them, read the insights.
AC is led by a Certified Engineering Technologist whose career has run from the inspection bench to launching new products into production.
Send a short note about the problem. We'll reply with whether we can help, and if we can't, who might.