Hii Pradeep... Greetings and welcome to the Cove ~~~
How to Reduce or Eliminate Inspection on an Assembly Line
By planing to Reduce or Eliminate Inspection on an Assembly Line ~~~
Easier said than done... But how again ?
First is the "will" to reduce and eliminate inspection on an assembly line.
This "will" will make you to plan for the reduction and elimination.
Plan to get the correct matching parts components within control such that variations do not affect the assembly.
Divide the assembly to such many stages so as to match with the skill and competency of the line personnel.
Provide suitable jigs and assembly fixtures that will prevent a wrong assembly and hence do not feed the next stages with defectives.
Train the assembly personnel about the work and make them aware what consequences will be faced by the customer when wrong work gets to his end.
At places where a validation is necessary, operator qualification is vital. Perform this and deploy such personnel at such stages.
The operator is the best inspector. Inculcate the sense of pride in the personnel who perform the assembly tasks.
Where possible identify such stages which will perform an assembly task as well as be responsible to approve the part upto such stage. Identify such skilled personnel at such stages.
Keep a constant monitoring and be prepared to take on risks and have the confidence of the management.
Remember that on an assembly line every person involuntarily inspects the part / sub-assembly he gets to his hands and when skilled enough he/she will quickly be able to detect a wrong. Respect this and encourage. The eyes see, the hands feel, the ears hear, the brain processes all these and gives a decision. All these are instantaneous. Do not think these are reducible or eliminatable inspection. You are encouraged to encourage this and take valuable feedback to your planning, so as to provide more clearer guidelines to assembly personnel.
Inspection is value addition only when performed scientifically and per plan. Inspection is built within the quality assurance process. It does not add value when you over-blow it and then see no value added.