AIAG Control Plan Manual

[Woody]

There is now a requirement for periodic verification of 100% Visual Inspection.

How does one define 100% Visual Inspection?

 

[gakiss2]

My understanding is that all of the parts (100%) are inspected visually. As opposed to 200% inspection in which each product is inspected twice.

 

[Johnny Quality]

I would define 100% visual inspection is that every part is visually inspected.

Inspected for what and by what method, that needs to be determined by your organization and possibly your customer.

 

[ABC Warrior]

It's exactly what it says on the tin. 100% eyeball inspection hopefully with instructions on lighting, time to inspect, distance of viewing etc. of feature or features relevant to the requirement. Verification of inspection success can be done using red rabbits, firewall verification of original inspection, regular re-training of inspectors using known defects and border samples plus loads more.

 

[Woody]

With a few replies, perhaps my dilemma is more clear - and something that I didn't want to mention in posing the question, is that none of our products are only 100% visually inspected. We stamp body panels for automobiles. There are some visual defects that - guess what? - we visually inspect 100%. Can I call a visual inspection GRR a suitable verification method?

 

[ABC Warrior]

With a few replies, perhaps my dilemma is more clear - and something that I didn't want to mention in posing the question, is that none of our products are only 100% visually inspected. We stamp body panels for automobiles. There are some visual defects that - guess what? - we visually inspect 100%. Can I call a visual inspection GRR a suitable verification method?

Yes, gauge R&R can be done on attribute data, but you need a set of very borderline pass/fails for visual standards that (for example) your premier expert/customer may set and use these as the masters. These (I'd recommend at least 30) can then be used to do a pass/fail study . You need multiple parts, multiple inspectors and multiple inspections and calculate repeatability and reproducibility. Make sure they are above 90%

 

[Bev D]

The requirement applies to any characteristic that is 100% visually inspected

Yes an attribute GRR is how you verify 100% visual inspection. I think of it as calibration for inspectors. Did it all the time for visual inspection.

If you check out my resource on Validating Measurement Systems (in the resources section) you will find many tips and methods and formulas. Free - Verification and Validation of Measurement Systems - Elsmar Cove Quality and Business Standards Discussions

I also have EXCEL spreadsheet in resources with the two common methods (Kappa and McNemer’s). Free - MSA Tools - Elsmar Cove Quality and Business Standards Discussions

For visual inspection of critical characteristics I recommend a Kappa score of at least 98. I do not recommend simple agreement.