Quality Boundary Samples

T

TownDawg

Greetings everyone. I'd like to request your help regarding this email I got:

Chris -- I would like to see if you would help with writing the mechanics of the “Function” & “Procedures” portion of the boundary board system we’re developing. I feel you have a better understanding of what we are looking for and you have a lot more work experience and QA knowledge to call on for this project. The attached is the format we will be using for these guidelines.

I truly wish I had taken better notes when I was out in the corporate office a few weeks ago.. but I’m been looking through several of my old emails and I think I’ve gathered up some ideas. The challenge will be to see if I can recreate that image in my mind again.

RE: Quality Boundary Samples -- Would any of you happen to have any verbiage on defining the "intent", "purpose", 'definitions", "examples of terms" that you might share with me and this forum?


:agree:
 

howste

Thaumaturge
Trusted Information Resource
I'd love to help, but I don't really understand what you're asking for. Are you developing boundary boards or writing a procedure? :confused:
 
T

TownDawg

I'm helping them write a procedure.. that describes what a boundary board is for.. and also ensures that all of us at the respective manufacturing locations do it the same.

For example, in the "FUNCTION" section of the document, i have this written so far:

The intent is to clearly communicate the “meaning” of each grade/category/level to our employees through the use of samples and photographs.

Essentially the logic is as follows:
  • When we audit/inspect/observe a part we first decide is the part is “good”. If the answer to the first question is “yes” then there is “no defect found” and the part is a category 4.
  • If we note some sort of defect on the part, then our next question is “is the defect severe enough that we need to pull stock” and if the answer to that question is “yes” then the part is a category 1.
  • If we don’t feel the need to go through our inventory (or hold the last truck, or 100% verify the order), then we have to decide if we are going to reject the part, and if the answer to that question is “yes” then the part is a category 2, else it is a category 3.

What I have written so far in the "PURPOSE" section is this:

"Although the general QA specifications go a long way toward defining the message we are trying to communicate, the use of quality boundary boards is an effort to clearly communicate the “meaning” of each grade/category/level to our employees."


I guess you need a little more information also.. we have a "DEFECT CODE LISTING" -- things like "10 - Scratched, Dented", and "14 - Excessive Flash"..

The purpose of the boundary board would be to help our employees understand what amount (and location) of a scratch would be acceptable, or what constitutes "excessive flash"..

Make more sense now?
 

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bobdoering

Stop X-bar/R Madness!!
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I could write quite a few thoughts on this, but time limits me to one important one right now: Make sure your boundary samples are in your gage calibration system. These samples have an opportunity to deteriorate over time, and need to be verified as accurate for their original intent from time to time.
 
T

TownDawg

Agreed Bob. (we are not automotive by the way).. but yes -- totally agree.

I want to focus on the documentation supporting the "how", the "why"..when you get time, please feel free to chime in.

I want a document that describes to each of the manufacturing locations:

  • How these boards should be constructed (recognizing that because of our manufacturing (process) diversity this will be a challenge), and
  • Why these boards should be constructed.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
(we are not automotive by the way)

That is good to know, but automotive is a good benchmark for such a system.


How these boards should be constructed (recognizing that because of our manufacturing (process) diversity this will be a challenge), and

You need to have it readable and reviewable from a reasonable distance from the board. (Don't you hate those billboards you can't read at 65 mph?) Magnified pictures can help. Don't forget your bi-focal associates. The higher the board, the more neck injury. Depending on the condition being observed, may want the sample chained to the board so that they can be viewed closely at any ambient light angle. Bottom line - one size might not fit all if the variation of conditions on the board are many.


Why these boards should be constructed.

They are constructed to provide clear, consistent, controlled criteria for conditions that can not be measured for pass/fail (generally visual or tactile conditions: burrs, discoloration, damage, etc.) An improvement over urban legend ("We always passed them looking like that").
 
T

timference

If you are writing a procedure for how to create boards, I would try to keep it as simple as possible. Basically, select the samples, have them approved by engineering as good and bad, train the operators. there your done. An elaborate procedure is not needed.

Also, you want to perform an attritribute R&R study to ensure the operators interprete the board properly. take 10-15 samples that are a mox o good and bad and tst 3-4 operators (or all of them as training) and ensure the operaters are on the same page.

I have been is quality for 20 years and have performed hundres of audits both internally and externally. Also hundreds of audits performed by others I have been the representatives. both being the auditor and auditee the biggest problem I've seen is to many procedurts and procedures that are to detailed. Remeber if you have a procedure, you need to do it that way. Keeping the porcedure simple allows some leeway int he process.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
Also, you want to perform an attribute R&R study to ensure the operators interpret the board properly. take 10-15 samples that are a mix of good and bad and test 3-4 operators (or all of them as training) and ensure the operators are on the same page.

Excellent ideas - they are attribute gages, and an attribute gage R&R will determine if the samples are clear enough for the job!
 
T

TownDawg

All good stuff.. taking notes.. and writing the procedure as I read those all this good information.
 
T

TownDawg

BOUNDARY BOARD GUIDELINES

PURPOSE
Boundary samples are used as a supplement to the part inspection standard (e.g. visual or sensory) when the characteristics are difficult to define or communicate by any other method. Although the general QA specifications go a long way toward defining the message we are trying to communicate, the use of quality boundary boards is an effort to clearly communicate the “meaning” of each grade/category/level to our employees.

SCOPE
This procedure is applicable to all [company name] facilities.

DEFINITIONS
A. Category 4 – Not defective.
 When we audit/inspect/observe a part we first decide if the part is “good”. If the answer to the first question is “yes” then there is “no defect found” and the part is a category 4.​

B. Category 1 – Piece cannot be installed as is; needs rework or remake.
 If we note some sort of defect on the part, then our next question is “is the defect severe enough that we need to pull stock” and if the answer to that question is “yes” then the part is a category 1.​

C. Category 2 – Likely to result in customer complaint; needs rework or remake.
 If we don’t feel the need to go through our inventory (or hold the last truck, or 100% verify the order), then we have to decide if we are going to reject the part, and if the answer to that question is “yes” then the part is a category 2, else it is a category 3.​

D. Category 3 – Not likely to result in customer complaint; acceptable “as-is”.
 Acceptable “as-is” - Meeting/exceeding our customer’s expectations.​

E. Station Boundary Board – Defect samples displayed in each work station showing the possible defects that can occur at the station.

F. Cell Boundary Board – Defect samples displayed in each cell packaging area showing the possible defects that can occur in the cell.

FUNCTION
• The intent is to clearly communicate the “meaning” of each grade/category/level to our employees through the use of samples and photographs. Proposed boundary samples must be representative of confirmed process capability and be consistently achieved.

• They are constructed to provide clear, consistent, controlled criteria for conditions that cannot be measured for pass/fail; e.g., visual or tactile conditions - burrs, discoloration, damage, etc.

An improvement over urban legend ("We always passed them looking like that").​

• Preliminary boundary samples should be discussed prior to tooling and process development to determine quality expectations and process capability.

 Boundary samples may also be created to define problems discovered in both production preparation and mass production stages.​
PROCEDURE
• Select The Samples
 Study the VMP for each operation, and determine what defects would be typical for this process by reviewing the content listed under “quality checks.” Use the defect code listing to organize and plan how many samples you will need, and which locations are applicable. Remember that the individual Station Boundary Boards will contain samples of the possible defects that can occur at the station, while the Cell Boundary Boards contain samples of all the possible defects that can occur at the cell.​

 Collect samples (and photographs) of defects to enable the operator to determine if the observed defect is acceptable, marginal, or not acceptable. In some cases, the condition cannot be described with a photo, and for those conditions we could gather that physical example under each picture or in an area all to themselves.​

• Construct The Boundary Boards
 Help our employees to associate color coding with the quality concepts. Although “one size fits all” is the goal, recognize that because of our manufacturing (process) diversity this will be a challenge.

 They need to be readable and reviewable from a reasonable distance from the board. Magnified pictures can help.

 The higher the board, the greater potential for neck injury.

 Depending on the condition being observed, may want the sample chained to the board so that they can be viewed closely at any ambient light angle.​

• Engineering / Sales and Marketing Approval
 Essentially these are attribute gages, and should be treated like a 1st article inspection process to ensure that all interested parties agree if the observed defect is acceptable, marginal, or not acceptable. A minimum of four equivalent sets of boundary samples must be prepared and sent to Corporate Quality Assurance for review.

 Boundary sample approval is based on internal quality standards, consumer acceptance impact, part design characteristics, and supplier process capability.

 After approval, one set will be retained by Corporate Quality Assurance as a master, and the remaining boundary samples will be provided to the individual locations to be used as a working set.

NOTE: Certain processes may require additional samples, please consult with Corporate Quality Assurance for specific quantity requirements.​

• Train The Operators
 Perform an attribute R&R study to ensure the operators interpret the board properly. Take 10-15 samples that are a mix of good and bad and test 3-4 operators (or all of them as training) and ensure the operators are on the same page.​

• Maintenance Of Boundary Boards
 The boundary samples should be located at the point of decision and should also be protected from damage or degradation.

 Physical samples have an opportunity to deteriorate over time, and need to be verified as accurate for their original intent from time to time, and should be part of a methodical review process.​




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That's a rough draft of what I have so far -- what else does it need to be complete?
 
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