J
Jason PCSwitches
Re: "Detection, NOT Prevention!!!!"
What standard is your company certified to??
What standard is your company certified to??
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Wes Bucey
Prophet of Profit
Re: "Detection, NOT Prevention!!!!"
It appears that, at its heart, your operation is really a "job shop" regardless of the dollar [pound sterling] amount of an individual order or the total business a customer does in a year. Job shops have special challenges in inability to use SPC on short runs and inability to use Design of Experiments techniques to determine optimum manufacturing methods. Thus, job shops are inherently less efficient than long-run operations. That does not mean they also have to be less effective.
I agree "education" is a key component of changing status quo, but first you have the problem of building a consensus among your fellow middle managers that a problem actually exists before you can even begin to work on a solution.
As a consultant experienced in such situations, it can still take me days or even weeks before I can learn enough about individuals involved to have an idea of the "triggers" which will involve them enough to consider the organization's problem as one which affects them personally. Sometimes it's financial, sometimes it's pride. It can even be loyalty to other employees. Whatever the trigger, it has to be found or guessed to engage them in arriving at the consensus a problem exists. Often, I will try to include as many possible triggers as I can think of when interacting with them in hope I hit one which works and evokes a responsive chord.
You might read through this old post of mine where I discuss how I empowered our operators in "error proofing" production to prevent nonconforming material reaching a customer. The same thing may not work for you, but perhaps it will give you ideas of what may work.
It appears that, at its heart, your operation is really a "job shop" regardless of the dollar [pound sterling] amount of an individual order or the total business a customer does in a year. Job shops have special challenges in inability to use SPC on short runs and inability to use Design of Experiments techniques to determine optimum manufacturing methods. Thus, job shops are inherently less efficient than long-run operations. That does not mean they also have to be less effective.
I agree "education" is a key component of changing status quo, but first you have the problem of building a consensus among your fellow middle managers that a problem actually exists before you can even begin to work on a solution.
As a consultant experienced in such situations, it can still take me days or even weeks before I can learn enough about individuals involved to have an idea of the "triggers" which will involve them enough to consider the organization's problem as one which affects them personally. Sometimes it's financial, sometimes it's pride. It can even be loyalty to other employees. Whatever the trigger, it has to be found or guessed to engage them in arriving at the consensus a problem exists. Often, I will try to include as many possible triggers as I can think of when interacting with them in hope I hit one which works and evokes a responsive chord.
You might read through this old post of mine where I discuss how I empowered our operators in "error proofing" production to prevent nonconforming material reaching a customer. The same thing may not work for you, but perhaps it will give you ideas of what may work.
B
bettsaj
Re: "Detection, NOT Prevention!!!!"
ISO9001:2008..... I've also been tasked with achieving ISO14001
ISO9001:2008..... I've also been tasked with achieving ISO14001
J
Jason PCSwitches
B
bettsaj
Re: "Detection, NOT Prevention!!!!"
The setters do thier own inspection and monitoring,,, I can see why you said that, but if they do thier own inspection then that part of the standard is covered as it's recorded on the job cards too. However.... The obvious fact is they don't or can't inspect thier own parts.....
Firstly i need to ensure that the information they are providing is correct.. and it's not then they need training.
The setters do thier own inspection and monitoring,,, I can see why you said that, but if they do thier own inspection then that part of the standard is covered as it's recorded on the job cards too. However.... The obvious fact is they don't or can't inspect thier own parts.....
Firstly i need to ensure that the information they are providing is correct.. and it's not then they need training.
J
Jason PCSwitches
Re: "Detection, NOT Prevention!!!!"
Why "can't" they inspect their own parts? If they are recording in-process inspection than those records are auditable. You can use those during an internal audit or during an investigation related to nonconforming product or customer returns to determine where the issue originated.
If you haven't already, investigate the case you mentioned while you were on holiday. Pull the records and try to determine the process where the defect originated. This will give you hard evidence to present & help support your case.
If all the records reflect everything was good you have an even bigger problem and though it will take more investigating, it could help your case even more.
Why "can't" they inspect their own parts? If they are recording in-process inspection than those records are auditable. You can use those during an internal audit or during an investigation related to nonconforming product or customer returns to determine where the issue originated.
If you haven't already, investigate the case you mentioned while you were on holiday. Pull the records and try to determine the process where the defect originated. This will give you hard evidence to present & help support your case.
If all the records reflect everything was good you have an even bigger problem and though it will take more investigating, it could help your case even more.
B
bettsaj
Re: "Detection, NOT Prevention!!!!"
They inspect thier own work, but don't record figures (sizes, etc) they just sign the doc to say "yes it's ok" and then run the machine..... The inspection record is next to worthless.
Also the issue that happened whilst i was on holiday, I know the root cause of that. I've already established that the engineering manager drew up the DXF file for the laser machine, and drew 2 holes at the wrong size. He should have got it screen checked by his collegue but obviously didn't as it would have been discovered before it hit the shop floor.
He's since held his hands up and admitted it was his error, but in his words "mistakes happen... i'm only human". The system failed because he didn't get it checked... As he's the engineering manager he probably deemed himself not worthy of getting checked by one of his co-workers.
There is currently no formal register to log DXF's that have been screen checked, although they do sign off the job card if it was done. I thjink i need to dig out the original job card and see if it was signed off... i suspect it wasn't
They inspect thier own work, but don't record figures (sizes, etc) they just sign the doc to say "yes it's ok" and then run the machine..... The inspection record is next to worthless.
Also the issue that happened whilst i was on holiday, I know the root cause of that. I've already established that the engineering manager drew up the DXF file for the laser machine, and drew 2 holes at the wrong size. He should have got it screen checked by his collegue but obviously didn't as it would have been discovered before it hit the shop floor.
He's since held his hands up and admitted it was his error, but in his words "mistakes happen... i'm only human". The system failed because he didn't get it checked... As he's the engineering manager he probably deemed himself not worthy of getting checked by one of his co-workers.
There is currently no formal register to log DXF's that have been screen checked, although they do sign off the job card if it was done. I thjink i need to dig out the original job card and see if it was signed off... i suspect it wasn't
J
Jason PCSwitches
Re: "Detection, NOT Prevention!!!!"
There are several issues here. What action was taken to eliminate the cause of the defect? What about failing to meet customer requirements? Customer satisfaction? What records do you have demonstrating the product met the requirements prior to release?
Even if they only truly inspect at final inspection/prior to shipment, they are suppose to have records demonstrating the product requirements/characteristics have been met. Do they??
There are several issues here. What action was taken to eliminate the cause of the defect? What about failing to meet customer requirements? Customer satisfaction? What records do you have demonstrating the product met the requirements prior to release?
Even if they only truly inspect at final inspection/prior to shipment, they are suppose to have records demonstrating the product requirements/characteristics have been met. Do they??
B
bettsaj
Re: "Detection, NOT Prevention!!!!"
in a word..... No. Not at despatch.
in a word..... No. Not at despatch.
J
Jason PCSwitches
Re: "Detection, NOT Prevention!!!!"
Write it up. If you don't your letting it go & it could come back to haunt you during an audit. It could be classified as inadequate internal audits, then you'll have to carry the blame.
You can use this as an opportunity to get your foot in the door. Move slowly & tactfully. Don't point blame & most importantly, show the relation to the bottom-line to get managements attention.
If they turn the blind eye, well, you did your part.
in a word..... No. Not at despatch.
Write it up. If you don't your letting it go & it could come back to haunt you during an audit. It could be classified as inadequate internal audits, then you'll have to carry the blame.
You can use this as an opportunity to get your foot in the door. Move slowly & tactfully. Don't point blame & most importantly, show the relation to the bottom-line to get managements attention.
If they turn the blind eye, well, you did your part.
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