Am I silly to do a 100% inspection?

G

goddha

#1
Dear all,

I m going through a decision whether to make a 100% inspection of all my products from my production line. in any production of mine, the population could be as small as 1 and as big as 160. on average i would say the population is about 50 on every production line.

My inspection consist of 4 inspections on the dimensions. Now i m pondering really hard if this decision to make a 100% inspection is stupid and if there is an even more effective way of sampling.
 
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jerry_Malaysia

Quite Involved in Discussions
#2
Re: M i silly to do a 100% inspection?

Dear all,

I m going through a decision whether to make a 100% inspection of all my products from my production line. in any production of mine, the population could be as small as 1 and as big as 160. on average i would say the population is about 50 on every production line.

My inspection consist of 4 inspections on the dimensions. Now i m pondering really hard if this decision to make a 100% inspection is stupid and if there is an even more effective way of sampling.
My personal opinion is that 100% inspection is a MUDA..... Though i am a QC person for almost 15 years now, I still think that it is a waste to do inspection. However, inspection could not be avoided in manufacturing, and inspection level should be decided based on many criteria, such as process capability, machine capability, severity of failure, whether it is fit to function, whether it is a Special characteristic..... etc etc

Nothing is stupid, you just have to analyze on which inspection level is required and will be beneficial to your organization
 
U

Umang Vidyarthi

#3
Re: M i silly to do a 100% inspection?

Dear all,

I m going through a decision whether to make a 100% inspection of all my products from my production line. in any production of mine, the population could be as small as 1 and as big as 160. on average i would say the population is about 50 on every production line.

My inspection consist of 4 inspections on the dimensions. Now i m pondering really hard if this decision to make a 100% inspection is stupid and if there is an even more effective way of sampling.
Depends upon criticality of the product/dimension. Normally, 100% inspection is considered a waste of time & money. How much is your rate of rejections with 100% inspection? If it is within your set limit, then you may switch over to sample inspection and choose your AQL. If the rejections are high, then this indicates that your process is not in control. In that case you will have to improve upon your process.

Hope this helps

Umang :D
 
G

goddha

#4
Re: M i silly to do a 100% inspection?

Thanks Jerry and Umang.

Currently I m trying to implement process capability to determine my thoroughness of the inspection.

My boss on one hand wants me to do a 100% sampling so as to give a quality assurance to the customers yet on the other hand he doesnt want to waste the manpower on all the inspection and of course the time saved from all the measuring.

Hence i m right now in a dilemma, how to strike the right balance in letting him have a close to 100% confidence on the product specifications and of course reducing manpower.

Would i be able to acheive a close to 100% confidence without doing a 100% sampling on my ave population of 50 products? my products on general usually falls well in the passing category however there might be some occasional problems where i have to assess the production line.
 

jerry_Malaysia

Quite Involved in Discussions
#5
Re: M i silly to do a 100% inspection?

Thanks Jerry and Umang.

Currently I m trying to implement process capability to determine my thoroughness of the inspection.

My boss on one hand wants me to do a 100% sampling so as to give a quality assurance to the customers yet on the other hand he doesnt want to waste the manpower on all the inspection and of course the time saved from all the measuring.

Hence i m right now in a dilemma, how to strike the right balance in letting him have a close to 100% confidence on the product specifications and of course reducing manpower.

Would i be able to acheive a close to 100% confidence without doing a 100% sampling on my ave population of 50 products? my products on general usually falls well in the passing category however there might be some occasional problems where i have to assess the production line.
100% inspection sometime do not require additional time or effort. It depends on the items that you want to measure. If you could build a go/no go gauge onto a working bench, where the semi finished products is going to sit on the gauge during processing, then it is automatically checked for fitting during the manufacturing process
I have done quite a few example, but it is very difficult to explain in words. Hope you understand what i meant.
Also, you may consider control the process parameter in order to achieve consistency in product, hence increase the confidence level. But you have to know the correlation of each process parameter with respect to the product quality.
Hope this help:2cents:
 
G

goddha

#6
Re: M i silly to do a 100% inspection?

100% inspection sometime do not require additional time or effort. It depends on the items that you want to measure. If you could build a go/no go gauge onto a working bench, where the semi finished products is going to sit on the gauge during processing, then it is automatically checked for fitting during the manufacturing process
I have done quite a few example, but it is very difficult to explain in words. Hope you understand what i meant.
Also, you may consider control the process parameter in order to achieve consistency in product, hence increase the confidence level. But you have to know the correlation of each process parameter with respect to the product quality.
Hope this help:2cents:
I think i understand where u are coming from. If i were to implement a go and no go gauge onto the working bench. would there still be a need to actually do random sampling of the product even after going through the go and no go gauges?
 
#7
My inspection consist of 4 inspections on the dimensions. Now i m pondering really hard if this decision to make a 100% inspection is stupid and if there is an even more effective way of sampling.
As others already said, that rather depends on what you are inspecting and the consequenses of failing to meet specifications. Other questions are where and how inspection is carried out: As Jerry hints, it does not necessarily have to end up in using a lot of extra manpower. A go/no go gauge is often a good idea, and it also puts the task firmly where it belongs: With the operators. Once, many years ago, when I visited two gear manufacturers I had a moment of revelation. Both companies were of similar size, but followed quite different doctrines:

In one of them ~10% of the entire staff turned out to be employed by a specific inspection dep.

The other one had not a single dedicated inspector... All inspection was performed in process by the operators, who incidentally had been given a couple of hundred hours worth of training each.

I don't suppose I really need to tell anyone which company turned out the best products for the best prices?

If you scroll down below the last post of this thread you will find some links to similar discussions. In this case they lead to previous questions about the efficiency of 100% inspection. You may want to have a look at some of them.

/Claes
 

jerry_Malaysia

Quite Involved in Discussions
#8
Re: M i silly to do a 100% inspection?

I think i understand where u are coming from. If i were to implement a go and no go gauge onto the working bench. would there still be a need to actually do random sampling of the product even after going through the go and no go gauges?
I personally think that if you have an effective go no go gauge in the production line, you may not even need to random sampling. But it must be very very effective, ie no miss. (in terms of gauge capability)
Also, if your working bench is auto type, ie transporting by auto conveyor, you might be in low risk ie you would not have miss checking case. But if it is transported manually, ie operator loading it to working bench, then you may have that problem.
Whether or not needing a random sampling, you have to assess it in detail before making the decision.
 

somashekar

Staff member
Super Moderator
#9
Re: M i silly to do a 100% inspection?

I think i understand where u are coming from. If i were to implement a go and no go gauge onto the working bench. would there still be a need to actually do random sampling of the product even after going through the go and no go gauges?
Added to all the good points do remember that 100% inspection will not give 100% assurance that 100% of your products are 100% good.
What I mean is 100% inspection in itself is not to be getting a feeling that "All is well"
The more rigerous this inspection becomes, the more problems it itself creates.
It is more about good process control, proper and scientific checks established at stages that gives a good end output, and a scientifically established sampling plan to inspect that assures quality.
It should be quality assurance and not quality control.
 
G

goddha

#10
Re: M i silly to do a 100% inspection?

thanks jerry and somas,

I agree with what somas have said and i will try to see what is appropriate for implementation to my organisation. Definitely the more thorough the inspection the more control i will be able to have over my process.

i would like to know if there are any go/no go gages that you can recommend me to?
 
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