Re: Implementing Operator Product Self-Inspection
For past 8 years of watching operators controling their own work I have experienced:
- recording results from never performed measurements (found by audit done by QA eng)
- preparing special samples for measurements (extra careful operation to get good results)
- measuring until 3 good samples are collected > recording only good results > continuing production
- pulling just-out-of-spec measurements into specification
- preparing samples for measurement few days in advance
- building samples from previously selected materials
- not following measurement instructions/frequencies
- and I am sure many other deviations I am not aware of.
The motive is efficiency, material consumption linked bonus and yield linked bonus. Operators try to hide problems for their short term benefits.
Please consider this and implement preventive measures before you implement self-control. These can be:
- regular audits by independent (non production bonus driven) QA people
- regular quality awareness trainings
- discipline actions for people who intentionally do not follow clear rules
- I have lately implemented Control Plan measurements to be done by Quality Inspectors for 4 weeks in one production line. I will collect the data and compare with what operators recorded previously. I am going to analyze collected data and decide what to do further (extensive training for production and re-implement self-control, implement Quality Inspectors for other production lines).