How to apply Incoming (Receiving) Inspection to Customer Supplied Material?

[nkson]

Hello everybody,
Our company starts of TS16949, and I encounter some problem during making Work instruction for Incoming Inspection. Let me explain in detail:
- Our company makes automotive part, and only have 1 customer. This customer supplies all material to us, we just assemble, final inspection and send F.G back to them.
- The material takes about 4 weeks to go from customer to our plant.
- The Acceptance Level of automotive is Zero defect. But if we find defect parts during Incoming Inspection, we can't reject whole lot because if we do that, we don't have any material for production and plant shutdown. We also don't have enough person to verify 100% of lot.
- Currently, we don't apply Incoming Inspection but instruct operators during operation to find and segregate defect parts, and inform back to customer to get replacement.

TS16949 system requires Incoming Inspection, so what and how can I do to control the incoming quality in this situation?
Thanks for reading,
Nguyen Kim Son

 

[qusys]

Re: How to apply Incoming Inspection with customer supplied material?

Is there an agreement in place with your Customer regarding with the incoming material which it itself provides to you?
I see the application of 7.5.4 Customer property, because I am assuming that the the material is not purchased, but directly provided by your unique Customer.
I think you are conform to the standard, based upon the procedure you have set, to segragate defective material and then inform customer for replace.
You should also speak with Customer if they want to change procedure, but in this case you should increase resource. In this case this could carry to re-negoziation of the price of the provided service.
Hope this helps. Waiting for other feedback of other Covers. What about it?

 

[qusys]

Re: How to apply Incoming Inspection with customer supplied material?

I would like to also add to my previous post that you can also refer to acceptance criteria clause too ( 7.1.2), where sample plan for attibutes must be zero defects.
Criteria shall be established by the organization and , when requested, approved by the Customer. In this terms, I did reference to the agreement in place.

Hello everybody,
Our company starts of TS16949, and I encounter some problem during making Work instruction for Incoming Inspection. Let me explain in detail:
- Our company makes automotive part, and only have 1 customer. This customer supplies all material to us, we just assemble, final inspection and send F.G back to them.
- The material takes about 4 weeks to go from customer to our plant.
- The Acceptance Level of automotive is Zero defect. But if we find defect parts during Incoming Inspection, we can't reject whole lot because if we do that, we don't have any material for production and plant shutdown. We also don't have enough person to verify 100% of lot.
- Currently, we don't apply Incoming Inspection but instruct operators during operation to find and segregate defect parts, and inform back to customer to get replacement.

TS16949 system requires Incoming Inspection, so what and how can I do to control the incoming quality in this situation?
Thanks for reading,
Nguyen Kim Son

 

[somashekar]

Re: How to apply Incoming Inspection with customer supplied material?

Hello everybody,
Our company starts of TS16949, and I encounter some problem during making Work instruction for Incoming Inspection. Let me explain in detail:
- Our company makes automotive part, and only have 1 customer. This customer supplies all material to us, we just assemble, final inspection and send F.G back to them.
- The material takes about 4 weeks to go from customer to our plant.
- The Acceptance Level of automotive is Zero defect. But if we find defect parts during Incoming Inspection, we can't reject whole lot because if we do that, we don't have any material for production and plant shutdown. We also don't have enough person to verify 100% of lot.
- Currently, we don't apply Incoming Inspection but instruct operators during operation to find and segregate defect parts, and inform back to customer to get replacement.

TS16949 system requires Incoming Inspection, so what and how can I do to control the incoming quality in this situation?
Thanks for reading,
Nguyen Kim Son

When you say that you instruct your operator to find and segregate defect parts, you are applying the incoming inspection. If your instructions to find and segregate parts are documented in a systamatic way for the operator to follow, you have made your work instruction for incoming inspection.

 

[qusys]

Re: How to apply Incoming Inspection with customer supplied material?

Hi Somashekar ,
I agree with you about what you have said.
My previous posts went to that sense.
To add something, these work instruction could be also inserted in the related control plan, that could encompass processes from incoming to shipping.

When you say that you instruct your operator to find and segregate defect parts, you are applying the incoming inspection. If your instructions to find and segregate parts are documented in a systamatic way for the operator to follow, you have made your work instruction for incoming inspection.

 

[KIDDO]

Re: How to apply Incoming Inspection with customer supplied material?

What do you have recorded in the applicable FMEA?

We also have customer supplied material (castings) and our Shipper/Receiver completes a visual inspection for damage, rust, dunnage damage, part number and quantity (matches packing slip). We also have a reference guide with pictures showing what acceptable raw parts should look like for the Shipper/Receiver. The operators also have pictoral type instructions (quality alerts, operator instructions, inspection sheets with casting numbers)It works well for us.


KIDDO

 

[qusys]

Re: How to apply Incoming Inspection with customer supplied material?

It is a good point too.
However, based upon what the initial post reports, I think he makes reference to the single items of an unique pallet.
The castings could arrive packed in single big boxes in the receiving dock, where the receiver can make an overal control on the integrity ( either visible on the box or on the enclosed shipping documents), but only when the material reaches the production line, the operators/technican staff can see the eventual defective piece, but they cannot reject the entire lots cointaining all pieces, even though they are ok for assembly.
This was my understanding...

What do you have recorded in the applicable FMEA?

We also have customer supplied material (castings) and our Shipper/Receiver completes a visual inspection for damage, rust, dunnage damage, part number and quantity (matches packing slip). We also have a reference guide with pictures showing what acceptable raw parts should look like for the Shipper/Receiver. The operators also have pictoral type instructions (quality alerts, operator instructions, inspection sheets with casting numbers)It works well for us.


KIDDO

 

[nkson]

Re: How to apply Incoming Inspection with customer supplied material?

Thank you for all replying.
We don't have any agreement with Customer of Incoming inspection.
I also thought about applying 7.5.4 "Customer Property".
But at this time I was not sure of conformation with TS requirement 7.4.3.1 "Incoming Product Quality" if we don't have an individual Incoming inspection procedure in-place.
Currently, we only have procedure of Control NC Product mentioned about disposition of NC material, but not yet have any documented work instruction to show operators and QC how to verify suspect material (only verbal). If I make it, so no need any more Incoming Inspection procedure?

 

[harry]

Re: How to apply Incoming Inspection with customer supplied material?

I am not sure what kind of materials are you referring to. In the case of bulk materials (drums of cables or rolls/bales of fabric - as examples) you can't do much during incoming stage.

 

[nkson]

Re: How to apply Incoming Inspection with customer supplied material?

I am not sure what kind of materials are you referring to. In the case of bulk materials (drums of cables or rolls/bales of fabric - as examples) you can't do much during incoming stage.

Our material is cut parts cloth, leather (for seat trim cover), about 40,000 parts per lot.