In-Process Inspection Data?? How Much?

[Monya1]

Our company is currently developing processes and subsequent documentation for ISO9000 / 2000 (9002) and I am needing clarification about in-process inspection data collection requirements. We are a sheet metal fabrication facility.

When the operator performs in-process inspections, based on critical dimensions as defined by engineering and specified intervals, does the operator have to document the readings they take or can they simply check OK if the measurments conform to the required tolerances? If the dimensions fail inspection then we would have the operator document their readings and what they did to get the process under control.

On first piece we also have the QA Tech inspect the part and sign the Shop Traveler for each operation. QA tech does not record his readings unless we are required to do so by the customer on a First Article Inspection form.

Hope this is not too lengthy or confusing. Thanks for any help you can offer.

Mona

Monya,

I spent 18 months in a sheet metal fabricating facility. They were not certified, but were working to AS9000 requirements, as well as Aircraft Specifications patterned after AS9000. They used the Traveler as their Quality Plan. Like yours, every step of the process was defined with Inspection points, First Piece verification, drawings, procedures, etc.. A few Customer Auditors questioned this practice. They were told, quite simply, this is how we operate. case closed.
Having said that, Final Inspection required a full blown 100% Inspection, (sample) with readings recorded. The Customer Auditor also performed his/her own inspection on the sample. I believe the main reason to record readings/measurements is to insure that the Inspector actually does all the inspection required. To allow a check mark on the dimension shown on a document may be seen as too easy for someone to skip a step. If your traveler is large enough you may be able to record actual dimensions, but it may get lost. Then what happens? It happened a few times where people spent hours looking for a traveler that had fallen off or had been taken off. You must have an Inspection Group. Have your Engineer decide critical dimensions, record those measurements and initial/date the drawing. Keep that drawing right up to Final Inspection and you are there. JMHO
Welcome to the Cove

[Monya1]

Thanks Energy for your reply. We do most of the things you mentioned.

Mona

[M Greenaway]

Monya

I agree with energy that getting the operator to record an actual measured size does help in avoiding the inspection getting missed, or a cursory sign off by ticking a box without actually doing the check.

Also you might consider that if this data was recorded you could actually use it to statistically analyse the capability and performance of your process, which can be very a very useful tool.

If you do not need any of this then there is nothing to say you have to record the measured size, you could then consider that you were performing an attribute check (even though measurement was taken).