Bullfrog Spas 
Beginner level
Intermediate level
Track: Lean with Horizontal Flow

Inspect your process: Ensure quality at the true source

How process parameter inspection is better than product/output inspection

Format

Practitioner Presentation

Highlights

Gain a better understanding of the difference between products and process parameters on a manufacturing line. Hear why it is so important to move upstream and inspect these process parameters as much or more than the components, sub-assemblies or final products are inspected after they are made.

Overview

A legendary Ohio State University football coach is credited with saying, “There are only three things that can happen when you pass the football, and two of them [incompletion and interception] ain't good.” The exact same can be said of product inspection, where outcomes can either meet requirements (good), require rework (bad) or be scrapped (really bad). 

This practitioner presentation will provide a better understanding of the difference between products (or outputs) and process parameters (inputs which produce the product) on a manufacturing line. Hear why it is so important to move upstream and inspect (monitor, validate, control) these process parameters as much or more than the components, sub-assemblies or final products are inspected after they are made. If manufacturers want to build quality in rather than inspect quality out, and get true quality at the source, then it is necessary to absolutely know, understand, monitor and control what is happening at the most critical process variables. The process components of employees, materials, machines, methods and environment are where true quality happens. Manufacturers need to make product inspections merely a validation that process inspections upstream are in control and producing 100 percent good products and outputs.

Company

Bullfrog International, LC is the parent company of the Bullfrog Spas® hot tub brand. Amongst other innovative products, Bullfrog International designs and manufactures the world’s only luxury hot tubs with the patented JetPak Therapy System™. JetPaks® are modular jetted spa seats that allow the user to customize, interchange and upgrade their hot tub's jetted massages at any time. Founded in 1996, Bullfrog International is headquartered in the greater Salt Lake City, Utah metro area and currently distributes, licenses, and retails its products in the United States, Canada, Australia, New Zealand, Asia, South American, the Caribbean and Europe. Bullfrog International is privately held and, over the last decade, has been widely regarded as the fastest growing luxury hot tub manufacturer in the world. www.bullfrogspas.com

Presenter

Alan Robins served as Bullfrog Spas' vice president of operations for 18 years. He recently retired from full time work at Bullfrog, but continues in a part-time consulting and training role. Robins holds a bachelor’s degree in business management - operations from Brigham Young University and has over 40 years of experience in operations and quality management positions at manufacturing companies, including director of quality, vice president of operations, and vice president of manufacturing.

He has helped companies assess and improve their business and quality processes, including implementation of quality systems, lean manufacturing and quality process control. Robins has implemented quality processes and systems, including manufacturing processes and procedures, manager/leader training and improved quality reporting. He has worked with Bullfrog Spas’ customer service groups to improve internal business process and information systems and also overseen product development and engineering functions at Bullfrog Spas to ensure design for manufacturability.