Inspection Check and Validation of work from the previous operation

[Allanp]

Hi to you all,
We have a production line wit each operation performing a different operation to the product. The inspection process needs to involve, not only a check on their own work, but to validate the work from the previous operation. Does anyone have experience of this process and any pit falls or things to look out for. As I understand iot it will increase the opertunity of identifying an NCR by about 60% but I am not sure about that figure. I need to prepare a presentation on the implementation of this process so I need to research as much information as I can on the subject. Any information would help.

[Jennifer Kirley]

Welcome to the Cove!

One potential pitfall is production pressure. If there is management pressure for pieces turned out versus pieces turned out well, there will be no incentive to find problems at whatever point in the manufacturing stream.

Another potential pitfall is a lack of understanding of requirements; that would have to be ensured.

A third potential pitfall is protecting fellow operators.

All three of these can be addressed with good management practices.

How was the 60% NCR reduction figure arrived at?

[Umang Vidyarthi]

In Reply to Parent Post by Allanp

Hi to you all,
We have a production line wit each operation performing a different operation to the product. The inspection process needs to involve, not only a check on their own work, but to validate the work from the previous operation. Does anyone have experience of this process and any pit falls or things to look out for. As I understand iot it will increase the opertunity of identifying an NCR by about 60% but I am not sure about that figure. I need to prepare a presentation on the implementation of this process so I need to research as much information as I can on the subject. Any information would help.

I understand that different operations are performed on a battery of machines. Are they produced in batches or you have single cell system? If it is a single cell system, then on-line inspection can be conducted by using sensors & gadgets on the conveyer. This system does not affect your production, since the operator has nothing to do with the inspection. The only pitfall here is finance. If you find it expensive, then patrolling inspection is the cheaper but effective option. The patrolling inspector covers 10-12 machines in one round, so he visits each machine at every ten minute interval. The periodicity may vary as per the requirement. The major pitfall in this system is fake records. The unscruplous inspector just fills the records by fake figures within the specs. Another pitfall is that you don't have 100% inspection.

If you provide more details about your production system, then we will be able to help you better.

Umang

[somashekar]

In Reply to Parent Post by Allanp

Hi to you all,
We have a production line wit each operation performing a different operation to the product. The inspection process needs to involve, not only a check on their own work, but to validate the work from the previous operation. Does anyone have experience of this process and any pit falls or things to look out for. As I understand iot it will increase the opertunity of identifying an NCR by about 60% but I am not sure about that figure. I need to prepare a presentation on the implementation of this process so I need to research as much information as I can on the subject. Any information would help.

The number of activities involved in the operation depends upon your planning and line balancing. I believe you have production stages where each operator executes a series of activities. In our case we have defined the flow chart that typically has various processing stages and at defined crucial points we have introduced the quality checks. These checks are also online and involve various inspection activities.
We strive on inculcating the following golden rules :
An operator is the best inspector of his job.
An operator will not accept defective parts to his stage.
An operator will not deliver defective parts to his next stage.
Each stage activities in the flow chart is based on the typical knowledge, skill and expertise that is available. Every stage has marked bins to place defective assemblies or parts received. Such production line needs constant supervision and we have been hitting over 98% FPY (First Pass Yield) A drop in yield is mostly a new operator issue and very soon gets back into control.