Manufacturing facilities can appear chaotic to people unfamiliar with the environment. The facilities are typically filled with loud, complex machines of varying sizes that can operate at very high speeds. Three of the most important metrics that a production facility attempts to control are safety, quality and delivery.

The concept of safety focuses on minimizing the risk of harm to plant personnel, or minimize the number of near miss accidents or the occurrence of accidents in the facility. Caulfield Engineering investigates manufacturing facility accidents that result in property loss, injury or fatality. Our team is well versed in the principles of industrial safety, risk assessment and hazard analysis, and when an accident does occur, our cross functional team of engineers and scientists are prepared to investigate the accident and determine the root cause.

The engineers at Caulfield Engineering have developed state of the art quality systems for some of the largest manufacturing facilities in North America. Our team has investigated quality issues with products manufactured in various industries. We have conducted detailed analysis of part quality as delivered by original equipment manufacturers as well as tiered suppliers within the supply chain. Our engineers and scientists are trained and have direct experience in Advanced Product Quality Planning (APQP) and have significant experience in the assessment of product quality.

Meeting delivery metrics demands optimization of machine availability or uptime. The engineers at Caulfield Engineering have investigated manufacturing facility machine failures in several different industries. Our team works with plant personnel do identify the root cause of machine issues within manufacturing facilities and identify changes that result in better machine availability and improved product delivery.

The following are only a sample of our representative experience:

Consulted Industries

  • Automobile manufacturers
  • Automobile component manufacturers
  • Building material manufacturing
  • Mining equipment manufacturing
  • Tier 1, tier 2, and tier 3 suppliers

Areas of Expertise

  • Advanced product quality planning and control (APQP)
  • Production part approval process (PPAP)
  • Six-Sigma
  • Quality system design
  • Root cause analysis
  • Sampling plan design
  • Failure modes and effects analysis
  • Risk analysis
  • Hazard analysis
  • Failure analysis