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Classification of Suppliers & Control Plans to Reduce Receiving Inspection

Douglas E. Purdy

Quite Involved in Discussions
#1
In an effort to reduce the amount of Receiving Inspection, management is proposing a classification of suppliers where the Top Classification would only need to sample one container per lot at a given AQL, while the Middle Classification will have 25% of containers sampled per lot at a given AQL, and the Bottom Classification will have 50% of containers sampled per lot at a given AQL. They have not shared how the suppliers would be selected for the three classifications, but my question is how does one document this type of control on a control plan? Please share examples of how you document your supplier classification on a Process Control Plan.

Thanks,
Doug
 
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Jim Wynne

Staff member
Admin
#2
Re: Classification of Suppliers & Control Plans

In an effort to reduce the amount of Receiving Inspection, management is proposing a classification of suppliers where the Top Classification would only need to sample one container per lot at a given AQL, while the Middle Classification will have 25% of containers sampled per lot at a given AQL, and the Bottom Classification will have 50% of containers sampled per lot at a given AQL. They have not shared how the suppliers would be selected for the three classifications, but my question is how does one document this type of control on a control plan? Please share examples of how you document your supplier classification on a Process Control Plan.

Thanks,
Doug
You can create a document that describes the process, and then refer to the document from the control plan.

I'm not sure what your containers contain, but if you're using a statistical sampling plan and not doing random sampling, the confidence level of the plan is out the window. In other words, if the containers are holding parts, and there are say, 10 containers, and you specify that only x of the ten must be sampled, then your sample isn't representative of the lot, and the confidence level associated with the plan isn't applicable. Randomly choosing x containers isn't the same as randomly choosing x parts from them.
 

Kales Veggie

People: The Vital Few
#3
Jim is correct. The control method for the receiving inspection is the document.

The document should also contain the list of the suppliers and their classification. This document should be updated when a supplier changes classification (hopefully to the top classification).

Also look at if you can use skip lot for certain suppliers or eliminate receiving inspection completely for certain suppliers.
 

Douglas E. Purdy

Quite Involved in Discussions
#4
Jim is correct. The control method for the receiving inspection is the document.

The document should also contain the list of the suppliers and their classification. This document should be updated when a supplier changes classification (hopefully to the top classification).

Also look at if you can use skip lot for certain suppliers or eliminate receiving inspection completely for certain suppliers.
Kales,

Is there an industry standard sampling plan for skip lot?

Thanks,
Doug
 

Douglas E. Purdy

Quite Involved in Discussions
#5
Re: Classification of Suppliers & Control Plans

You can create a document that describes the process, and then refer to the document from the control plan.

I'm not sure what your containers contain, but if you're using a statistical sampling plan and not doing random sampling, the confidence level of the plan is out the window. In other words, if the containers are holding parts, and there are say, 10 containers, and you specify that only x of the ten must be sampled, then your sample isn't representative of the lot, and the confidence level associated with the plan isn't applicable. Randomly choosing x containers isn't the same as randomly choosing x parts from them.
Jim,

I realize that this plan proposed by management is not statistically sound, but I do not hold much sway in their decision making. They were performing some type of skip lot when I made it a finding in an Internal Audit. The finding was that the skip lot listing not being the same between Receiving and Receiving Inspection; their Inspection Plan said that the sampling was to ANSI Z1.4, and the Control Plan said nothing about Skip Lot.

I have prepared a sample Control Plan for Receiving Inspection of Plated Product (see attachment) that would be in conjuntion with RI Procedures abc, where this three tier classification of suppliers would identify the number of containers to be inspected. Is this what you are indicating in your response?

As for what the containers contain, in this case (and the majority of outside services) it is plated parts for the automotive industry.

Thanks,
Doug
 

Attachments

Douglas E. Purdy

Quite Involved in Discussions
#7
The following link is to info on ASQ's skip lot sampling plan, ANSI ASQC S1-1996:

http://www.asq.org/quality-press/display-item/index.html?item=T64E&xvl=76ES_T64E

It's designed to work with Z1.4

Geoff Withnell
Geoff,

If you went to incorporate a different sampling plan, like this skip-lot, how did you include it in the Control Plan and did you have to notify your customer(s) of this change? If you are able, would you share a snip-it of a control plan for an example?

Thanks,
Doug
 
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