Dears,
we are going to gradually replace QC performed by Quality Inspectors with Quality Self-Inspection performed by operators and Production Supervisors/Technicians.
In order to success doing that, we surely need to elaborate and implement a Quality Training Program for all the Production Functions:
- Operators
- Shift Leaders
- Technicians
- Production Supervisors
- Maintenance
- Management

Can you suggest me for each different role, which would be the best issues to train about and how to deploy the training program?
Did someone already make similar experience? Do you have training material or plans to share?

Thank you in advance.

I put all the inspection needs into the Work Instructions. You need to make it as simple as possible. Make sure the operators that are using gages are trained on how to read, maintain, the gages. Make sure you have a robust reaction plan they follow if something is out. You will also have to include operators IMO on your RR studies for the gages since they are using them.

Good Luck,
I have found that this is effective. My QA audit now instead of being the quality police. It also makes the statement we are all responsible for quality mean something.
Cheryl

Could you please explain more about this "robust reaction plan"?

Regards,

Alekra

We used to have a full time inspector in our print department that did nothing but sign off the first piece of each operation. He left and we decided to try creating a checklist that lead operators could use to check everything and sign off other operators. Lead operators are also authorized to sign themselves off. So far it has worked very well, and we are thinking about trying it in our other departments. It has given the operators more ownership and understanding of their processes.

I'm not clear why these people on your list would have differing inspection roles.

Here's a link to a nice inspection training plan: http://nepp.nasa.gov/whisker./reference/tech_papers/2005-HP-tin-whisker-training.pdf

That plan is complex, but it caught my attention because it explains at least two types of inspection error: variation between inspectors and parallax error from viewing things at an angle. Sampling plans must also be understood, obviously along with what is an acceptable nonconformity and what is a defect. Blueprint reading and geometric dimensioning & tolerancing may also be required. Care must be taken to ensure instructions are clear and the new inspectors understand how they can avoid alpha and beta errors: accepting bad parts and rejecting good parts.

Such topics are the sort that long-time inspectors might forget must be taught; it's not enough to just show a machinist how to enter data in a QC form and set him/her loose, which is what some organizations are inclined to do.

A reaction plan should include, at minimum step(s) for containment, such as stopping the process and finding/isolating all affected parts, and who to contact with what information regarding the discovery.