Quality systems and business process consulting
Processes that pass the audit, and still make sense on Monday.
ISO 9001 and AS9100 quality systems, built or repaired by someone who has run the shop floor, managed the plant and sat on the receiving end of the audit.
Services
What we take on
For manufacturers, machine shops and suppliers who need a quality system that works, or business processes that stop depending on one person's memory.
Quality system development
A complete quality management system, from gap assessment through documentation, training and readiness for your registrar's audit.
ISO 9001 · AS9100Internal audits and audit prep
Independent internal audits, findings you can act on, and preparation for certification or surveillance audits.
Internal audit · Management reviewProcess development
Mapping and documenting how the work is really done, so it can be trained, measured and handed over.
Process mapping · Procedures · Work instructionsProcess improvement
Finding the waste and the bottlenecks, then fixing them with the people who do the work.
Lean · 5S · KaizenRisk management
Risk-based thinking that satisfies the standard and is useful to the business, including failure mode analysis.
ISO 31000 · FMEA · DFMEASystems and data
Getting planning systems and master data into shape so the numbers can be trusted.
ERP · MRP · Master dataObjective evidence
Results on the record
An auditor asks for evidence, not adjectives. These are outcomes from Jim Rebensdorf's own career in operations and quality roles.
| Result | What was done | Area |
|---|---|---|
| 7 years, no major findings | Built an ISO 9001 quality system for a CNC machine shop and kept it registered as management representative through every third-party audit. | ISO 9001 |
| AS9100 system established | Set up a new quality system to AS9100 and ISO 9001, then ran it as QMS representative and internal auditor through successful certification audits. | AS9100 |
| $350K saved per year | Led a Kaizen team in composite manufacturing that removed that much annual cost. | Lean |
| 98% on-time delivery | 5S, Lean and Kaizen work on workflow and lead time in a production shop. | Lean |
| 99.2% equipment uptime | Rebuilt the preventive maintenance process, measured across key equipment in its first year. | Operations |
| Injury rate under 1.75 | Wrote the safety manual and injury prevention plan; recordable injury rate fell to that level within two years. | Safety |
| Four sites, one data standard | Wrote the master data specification for an SAP rollout and led its adoption across four facilities. | ERP |
Results from past employment. Every business is different, and past results don't guarantee yours.
Method
Plan, do, check, act
The same cycle the standards are built on, applied to the engagement itself.
- Plan
Assess the gap
We compare what you do today against the standard or the goal, and agree the scope and schedule.
- Do
Build it with your people
Processes, documents and training are developed alongside the staff who will use them.
- Check
Audit it
An internal audit and management review show what holds up and what doesn't.
- Act
Close the findings
Corrective actions are completed and the system is handed over ready to run without us.
About
Jim Rebensdorf
Jim learned machining from his father at 14 and has worked in manufacturing ever since: more than fifty years, in roles from machinist and manufacturing engineer to production manager and director of operations and quality.
He has worked in aerospace composites, precision machining and semiconductors, in shops of a dozen people and in multi-site corporations. That range is the point: a quality system has to fit the size of the business it serves.
- ISO auditor training and certification
- Rummler-Brache Process Improvement
- BP Group Certified Process Professional Master
- BS, Business Administration
Career includes McDonnell Douglas, Boeing, Hitco Carbon Composites, Romco Manufacturing, Solvay Composite Materials and Micron Technology.
Contact
Tell us where it hurts.
An audit date coming up, a finding you can't close, or a process nobody can explain. A short description is enough to start.
714-814-2200
jim@yniconsultingsolutions.com
YNI Consulting Solutions LLC · Camden, Tennessee