Determine if your final inspection practices are 'waste' or not

[Brizilla]

I agree with your premise. However, I don't agree with the unit numbers as presented.

Does it really cost $1 per piece to do a final inspection? Seems high.


Also, I think the cost of a defect reaching the customer is typically MUCH higher than $240, when you factor in all the time, meetings, responses, and other soft costs that are incurred. If my hunch is correct, the new numbers will reinforce your example significantly.

1$? Seems low.

We're a job shop/machine shop. If a significantly complicated hydraulic gland has 40-50 inspection points and by rule of thumb it takes 1 minute per point and my QA Tech makes $20/hour...

 

[Helmut Jilling]

1$? Seems low.

We're a job shop/machine shop. If a significantly complicated hydraulic gland has 40-50 inspection points and by rule of thumb it takes 1 minute per point and my QA Tech makes $20/hour...

What you are describing is obviously not a typical final inspection. It is almost a full layout. Also, a machine shop generally does perform a very comprehensive inspection if they perform precision machining. It is unlikely a machine shop would consider discontinuing detailed inspections, whether final or by the machine operator.

 

[Bev D]

... Also, a machine shop generally does perform a very comprehensive inspection if they perform precision machining. It is unlikely a machine shop would consider discontinuing detailed inspections, whether final or by the machine operator.

Well, there's a difference between discontinuing detailed inspections and significantly reducing the number of pieces inspected. With good Problem Solving, PM, Tool control, SPC and/or PreControl (YES, 'inspection' measurements in-process), simple mistake proofing (designed in is always cheaper than post design) etc. we can significantly reduce the final inspection requirements and total inspection load. Going to absolutely no inspection is the ideal state and as we've said before we don't ever get there but we keep movign in that direction...

 

[Brizilla]

What you are describing is obviously not a typical final inspection. It is almost a full layout. Also, a machine shop generally does perform a very comprehensive inspection if they perform precision machining. It is unlikely a machine shop would consider discontinuing detailed inspections, whether final or by the machine operator.

What I am describing IS our typical Final Inspection.
And yes we do comprehensive inspection during machining also.
And yep Final for now, is here to stay.

 

[Helmut Jilling]

Well, there's a difference between discontinuing detailed inspections and significantly reducing the number of pieces inspected. With good Problem Solving, PM, Tool control, SPC and/or PreControl (YES, 'inspection' measurements in-process), simple mistake proofing (designed in is always cheaper than post design) etc. we can significantly reduce the final inspection requirements and total inspection load. Going to absolutely no inspection is the ideal state and as we've said before we don't ever get there but we keep movign in that direction...

very well put...

 

[Icy Mountain]

I agree with your premise. However, I don't agree with the unit numbers as presented.

Does it really cost $1 per piece to do a final inspection? Seems high.

Also, I think the cost of a defect reaching the customer is typically MUCH higher than $240, when you factor in all the time, meetings, responses, and other soft costs that are incurred. If my hunch is correct, the new numbers will reinforce your example significantly.

My final inspection is a semi-automated test that requires a technician to monitor at $60 per hour (fully-burdened) and the test takes 1 minute. And you are correct, $240 is simply the cost of the dead unit I get to keep + the new one I had to send out, shipping, handling, 8D, etc. not included.