5 Why help needed Please kindly review

B

Bradley C Smith

#1
Ok I am trying to utilize the 5 why's down to a management issue does this appear ok?

Self Inspection NOK
Why? Visual inspection control method is not effective/robust for this type of failure mode.
Why? Based on Gage R&R, repeatability was less than 90% which shows that visual inspection is not adequate for this failure mode.
Why? No evidence that a Gage R&R was performed to validate the control method during the program phase.
Why? PFMEA RPN value is too low

Please critic if it can go farther or if this makes sense.
 
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Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#2
Hello,

I think it is worthwhile to identify whether visual inspection is warranted in this step or not, and I am unclear as to the role Gage R&R plays with this decision. My understanding has been that the type of inspection is determined while defining the control plan, and that GR&R is a tool to quantify and verify an instrument's ability to perform a mechanical inspection. So the purpose of GR&R seems to be misapplied, while the various fallibilities of visual inspection do not so far appear to be addressed.

I welcome other Cover's input, out of concern I may not have identified this issue correctly.
 
G

George Weiss

#3
Hello pretty-new cover,
.
The 5 WHYs’ evaluation is a look for a root cause. It is a basic tool/approach. An evaluation of your 5 WHYs would require knowing the problem better. Listing a problem, and requesting some offered suggested 5 WHYs would be one idea. Another would be allow forum brainstorming on your problem(s)

5 WHYs criticism:
  • Tendency for investigators to stop at symptoms rather than going on to lower level root causes.
  • Inability to go beyond the investigator's current knowledge - can't find causes that they don't already know Lack of support to help the investigator to ask the right "why" questions.
  • Results aren't repeatable - different people using 5 Whys come up with different causes for the same problem.
  • The tendency to isolate a single root cause, whereas each question could elicit many different root causes
Pulled from @


Wikipedia reference-link5_Whys
.
:bigwave:
 
B

Bradley C Smith

#4
We had a situation where we were visually checking at the workstation to see if 4 screws were fully seated down to secure a speaker to a door panel. Operator did not detect presence so we conducted an attribute gage R&R to see if they could visually detect screws being fully seated down = 0 gap. A 30 piece attribute gage R&R was done with 4 inspectors at various screw gaps 1.50 mm, 1.25 mm, 1.00 mm, 0.75 mm 0.50 to see if they could detect consistently. What we found was at 1.50mm was detected 100%. 1.25 to 0.75 there were non-detections, 0.75 and lower was always non-detected. So we validated that the measurement method was not correct.
 

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#5
We had a situation where we were visually checking at the workstation to see if 4 screws were fully seated down to secure a speaker to a door panel. Operator did not detect presence so we conducted an attribute gage R&R to see if they could visually detect screws being fully seated down = 0 gap. A 30 piece attribute gage R&R was done with 4 inspectors at various screw gaps 1.50 mm, 1.25 mm, 1.00 mm, 0.75 mm 0.50 to see if they could detect consistently. What we found was at 1.50mm was detected 100%. 1.25 to 0.75 there were non-detections, 0.75 and lower was always non-detected. So we validated that the measurement method was not correct.
What was the operational control? How are the screws set in? Is there some specific torque set for the screws at this step?
 
B

Bradley C Smith

#6
Torque tolerance is 0.90 to 1.10 Nm with atlas copco electric torque driver. Workstation operators are required to use electric torque driver and then visually check screws are seated. Driver is not poka-yoked to prevent part from going to next station that is why there is visual inspection.
 
B

Bradley C Smith

#7
Operational control is torque driver that torques 4 speaker screws down at between 0.90-1.10 Nm to secure speaker to door panel. Since torque driver is not error-proofed at the station we were relying on visual inspection to check that screws were seated fully down. Torque driver was found to be repeatable and does torque to those values.
 

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#8
Gage R&R is normally done with gages. If inspectors are less reliable than the torque value of the driver, why not use the torque driver to ensure proper torque?
 
B

Bradley C Smith

#9
What ensures that the torque seats all screws down in the event that there is an interference condition between the screw and the bottom of the screw boss which causes the screw not to sit flush? Torque is acheived however screw is not flush.
 
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G

George Weiss

#10
I hear the condition of variations in the pilot hole for the screw. I am guessing you are going through several soft materials, and securing to a sheet metal door panel. The variations in pilot hole are causing less than fully seated speakers. The speakers have a metal support frame also, it is expected. The sheet metal screws attaching metal to metal can handle quite a torque, unless the screws are of the cheapest brand. I am betting an evaluation of the screw shear/break torque will find you have ample room to increase torque to solve this problem. Max securing torque being 80% of shear/break, and allowing for 5-10% torque drive spec. The target is normally 60-70%. If I am totally off target, then of course disregard.
 
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