Control plan IATF non-conformity

[Bev D]

Or did a supervisor tell them it wasn’t important?

 

[Jen Kirley]

Lots of good comments so far.

There should have been a justification of why this was a major. The nonconformity's list of evidence is lacking needed detail .

I have some questions.

1. Was it happening throughout the organization - systematic?
2. Was it a repeat nonconformity?
3. Was product quality being compromised? (I get that there is apparently no inspection record if that's what these were).
4. What were these measurements - were they final inspections?
5. How are the operators provided with these forms?
6. What happens to the firms after they are filled out - what do the operators do with them?
7. Has this been happening a long time - how long?
8. What is the training for these operators?
9. How are the operators determined to be competent - what ensures they know they must fill out these forms?

I am still not sure it was their choice not to fill out the form.

 

[Jen Kirley]

If it was just one operator I could maybe buy into error. But this involved multiple operators. The questions I have asked are meant to help explore this part of the process.

I agree that it makes no sense to beat the peasants, metaphorically, unless the royalty wants to do the job themselves after all the peasants are gone. You need to talk with the operators. It should be the supervisors who do it, but as you said they don't care to and as Bev said the supervisor(s) might actually be the source of the dysfunction.

 

[Ashland78]

Lots of good comments so far.

There should have been a justification of why this was a major. The nonconformity's list of evidence is lacking needed detail .

I have some questions.

1. Was it happening throughout the organization - systematic?
2. Was it a repeat nonconformity?
3. Was product quality being compromised? (I get that there is apparently no inspection record if that's what these were).
4. What were these measurements - were they final inspections?
5. How are the operators provided with these forms?
6. What happens to the firms after they are filled out - what do the operators do with them?
7. Has this been happening a long time - how long?
8. What is the training for these operators?
9. How are the operators determined to be competent - what ensures they know they must fill out these forms?

I am still not sure it was their choice not to fill out the form.

I like your points. I was going to say the first thing you did. It appears the leadership there, that is in place doesn't understand they are responsible to meet these key customer requirements, to have engineering in place to monitor these things. They probably noticed this on multiple control plans, hence systemic.

 

[Ashland78]

If it was just one operator I could maybe buy into error. But this involved multiple operators. The questions I have asked are meant to help explore this part of the process.

I agree that it makes no sense to beat the peasants, metaphorically, unless the royalty wants to do the job themselves after all the peasants are gone. You need to talk with the operators. It should be the supervisors who do it, but as you said they don't care to and as Bev said the supervisor(s) might actually be the source of the dysfunction.

Consider leadership and engineers too. I am not sure that supervisors understand these key characteristics as much.

 

[Ashland78]

They are supposed to document measurement data in the log sheet.

My understanding was the key items being measured didn't link with the control plan. Which links to the customer requirements, right?

 

[Ashland78]

I had a very knowledge Quality Engineer professor that always instructed the process should be set up so the people don't fail, or won't fail. Sounds like there aren't systems in place to ensure this gets completed.

 

[Bev D]

Any decent ERP system can be set to not allow the parts to move forward (and set off alarms for ( OOS parts) and not allow financial transactions for shipments if the data isn’t entered.

 

[outdoorsNW]

This is a leadership problem, not an operator problem. If many operators do not perform the action, leadership at some level is the problem. It could be the leader of the operators, it could be someone higher up. You may need someone to explain why the data is important. You may need to verify the operator workload is not excessive.

Possibly a contributing factor is the data collection is excessive and you could redefine what is necessary. Automating data collection is a possibility.

 

[Emerald]

Thank you all for the inputs- they're all valuable. As a new member, I couldn't have asked for a better platform for guidance. I was able to change the direction of the root cause analysis from operator to systemic, and everyone seem to be onboard now.