A more integrated workflow helps improve order handling efficiency by connecting project management, production planning, and interdepartmental coordination. This structured approach ensures that each order progresses smoothly through every stage, reducing delays and minimizing errors.
WayKen always follows systematic and standardized processes to make quality a habit and delivery trustworthy.
The Rigorous Order Review Process
At Wayken, we ensure customer satisfaction through a rigorous order review process. This involves close collaboration between multiple departments with each team responsible for specific aspects of the process. We conduct a comprehensive evaluation of the order at every stage, and strictly adhere to ISO 9001 standards.
Let’s kick things off with the sales team receiving a customer’s purchase order.
When a client submits a purchase order, the project manager assigned to provide one-on-one service carefully checks the order details and any relevant information from the customer.
After that, they organize the necessary documents, upload them to the company’s internal order management system, and notify the engineering department to review the order. The order documents need to include the 2D and 3D design files for the parts、a complete parts list, and the production notification.
Once the sales department notifies them, the engineering team will promptly review the order documents. They’ll compare the order files with the initial quotation to ensure they match, check for any cost discrepancies between the order requirements and the quote, and make sure all the 2D and 3D files are complete and meet necessary standards.
After the review, if everything checks out, the engineering team will give their approval. Only after this approval, can the order move on to the production team for further inspection.
Then, the machining department is responsible for checking the completeness of the documents to ensure that our manufacturing processes delivery timelines, and quality standards meet the customer’s requirements. Meanwhile, the quality department reviews the customer’s acceptance criteria to ensure that our inspection and shipping standards align with their expectations.
If any issues are found during the order review process, the production team will document their feedback in the “Project Review Comments” and communicate promptly with the project manager to coordinate with the customer.
Leveraging DFM for Effective Communication
The full name of DFM is “design for manufacturing”. The objectives of DFM is to provide affordable machine options, and to optimize performance and redefine the product. WayKen use DFM to improve the mutual communications, in order to make the whole project smooth and orderly.
Before quotation, WayKen will communicate to customers’ engineers about a few key points that are important to WayKen’s internal quotation process. When both of them have no disagreements on the machining methods or surface treatments, WayKen’s engineering department will be able to provide accurate quotation.
More often, DFM communication will be likely appear when the quotation is sent and before productions start. Usually there’re more pieces of points to discuss, so for better reading experience, WayKen will use PowerPoint as the media of DFM communication.
And for some big projects, WayKen would have a project meeting with all involved engineers and inspection department before productions officially start. Mostly, they will discuss and confirm more details of each part with customers. For instance, the injection molding project. Before moving forward to production, WayKen team did an computer analysis about injection, and communicate everything with customer, and the customer determined about injection method, parting line, grade of shrinkage, and so on.
Certainly, there probably will also be similar communication after FAI, especially for batch production.
Full Production Part Approval Process（PPAP） Ensuring Consistent Quality
PPAP acts like the “final pass” before production. It verifies whether the product design is reasonable and whether the production process is fully prepared. Through PPAP, suppliers ensure that part quality meets standards, reducing the risks of rework, returns, or recalls after mass production.
The completion of PPAP indicates that the pre-production planning has been thoroughly implemented.
At WayKen, for batch projects especially low-volume CNC machining projects in the automotive industry, the manufacturing team strictly adhere to our customers’ PPAP process requirements. Before official mass production, the team carry out a systematic set of preparatory work, covering engineering design, production layout, quality planning, and more to ensure stable delivery for every subsequent batch.
1. Create a detailed process flow disgram
Especially in process inspection, WayKen meticulously plans machining processes based on customer drawings and matches them with suitable equipment and fixtures. For every critical dimension, WayKen define control methods and inspection measures.
2. Process failure mode and effects analysis
Before mass production, WayKen proactively identify potential risks in every stage, from incoming materials, processing, and inspection to packaging and transportation. For example, potential risks in the CNC process may include out-of-tolerance part dimensions burrs, etc.
Then, WayKen will develop preventions and detections such as implementing a tool management system that defines tool lifespan and usage standards to minimize risks at the source.
3. Standardize the inspection criteria
WayKen will work with the customer to define inspection methods including sampling plans such as 100% inspection or AQL.
Key dimensions will be identified using bubble diagrams, and for these critical dimensions, both parties will agree on the measurement tools to be used, such as calipers, pin gauges, CMMs, surface roughness testers, etc.
In-Process Quality Check (IPQC) During Production
At WayKen, during production, the quality department conducts regular inspections according to the plan. Inspectors use an in-process quality check (IPQC) list, which lists defects and how to handle them common defects include issues like materials, appearance, features, dimensions, assembly, and functionality.
When an inspector finds a defect, they record details like the description, quantity, location, and the person who found it. Then they notify the technician to adjust the machine and trace back to sort defective products, marking them as “scrap” or “rework” and storing them in designated areas.
This step prevents more defective products from being produced.
Besides, to boost production efficiency and ensure on-time delivery, WayKen has created a detailed production plan. This plan breaks down the project into a step-by-step schedule, which guides daily tasks and helps our team organize direct, and coordinate production.
