Quality means doing it right when no one is looking.
Henry Ford

Quality and Culture

Anybody who has worked on a factory floor or the back office knows that the best work instructions and the clearest processes still leave room for individual judgements and work habits. So unless full-automation is possible, the only way to reduce variance in an organization is if the individuals within the organization work and make judgements based on what they feel to be correct. This is where company culture and standards comes into play, for without the right culture and standards, it is not possible to have individuals work towards desired quality goals.

In Juscom, we have only one goal—to have zero product defects when goods leave our factory. To get there, we have nurtured a collaborative, open-office and open-door environment and culture that is highly unusual in Asia where hierarchical, structured company cultures are the norm.
In addition, we work to the strictest applicable quality standards in the industries we participate in. This means:
  • ISO/TS 16949 quality standards, a superset of ISO 9001 that requires random audits by customers and the certifying entity;
  • All internal work standards that meet or in most cases exceed IPC/WHMA-A-610 Class 3 and IPC/WHMA-A-620 Class 3 work standards. Class 3 quality is normally reserved for "high performance electronic products", that is, "products where continued performance or performance-on-demand is critical, equipment downtime cannot be tolerated, end-use environment may be uncommonly harsh, and the equipment must function when required, such as life support systems and other critical systems."
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All products—even simpler wire-harnesses—are 100% tested several times during the manufacturing process, and also just prior to packaging. If the product will be destroyed or adversely affected by testing, then we use random sampling based on ISO 2859-1 to sample and test, unless otherwise specified by the customer.

Wire-crimps, which if done correctly are more reliable than soldered connections, are tested several times per hour using non-destructive tests such as crimp width and height measurements. In addition, destructive tests such as pull-force measurement and cross-sectional analysis are performed routinely.

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Randomized incoming, in-process, and out-going tests are typically performed using ISO 2859-1 procedures for inspection by attributes on a lot-by-lot basis. Juscom typically uses a very stringent Acceptance Quality Level (AQL) of 0.25.

Dimension checks are performed with micrometers, digital calipers, and optical profile projectors (pictured at right). These instruments are calibrated and certified annually. In fact, even the simple steel rulers we use are subject to the same annual checks!

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