Error Proofing Verification - Layered Audit Question

Q

qwert98

#1
I understand how error proofing stations work, but as part of a layered audit I need to verify my error proofing stations. I know how to verify with simple stations ie. make a bad part, insert into the error proofing station and verify that it fails.

The question is how do I verify a station makes a part live? I have a station sets a voltage on a part, and another one that welds to a certain value. I can't force the machine to make a bad part. How do I verify that these stations work? Are these stations that I really need to error proof?

Thanks for the help!
 
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BradM

Staff member
Admin
#2
Re: Error Proofing Verification- Layered Audit Question

Hello, and welcome to the Cove!

As far as forcing error, I'm not sure what your part is, and whether Destructive Testing is an option.

However, I would submit to you that you can vary voltage and weld parameters. I'm not a welder, but have been around long enough to know there's a reason why you pay for a good welder. There are a lot of variables associated with welding. I would think those could be introduced.
 
Q

qwert98

#3
Re: Error Proofing Verification- Layered Audit Question

Thanks for the reply and the welcome!

I am looking how to verify an error proofing test in general where the test is part of a prcess. We have one automated process where a potentiometer is turned to a specific voltage. The error proofing is that the machine will fail a part if the specific voltage is not hit. I can't force it to hit the incorrect voltage (and therby fail the part), so I don't know how to verify that the station's error proofing is working.

I may not have to error proof these stations - I may be diving into this too deep...
 

BradM

Staff member
Admin
#5
Re: Error Proofing Verification- Layered Audit Question

Thanks for the reply and the welcome!

I am looking how to verify an error proofing test in general where the test is part of a prcess. We have one automated process where a potentiometer is turned to a specific voltage. The error proofing is that the machine will fail a part if the specific voltage is not hit. I can't force it to hit the incorrect voltage (and therby fail the part), so I don't know how to verify that the station's error proofing is working.
If you have a potentiometer to dial in the voltage, why can't you vary the voltage? I'm just confused, I guess. If you know that incorrect voltage can fail the part, then adjust it and fail the part. By varying the voltage, you can determine what the acceptable range is.


Every process has error; one just needs to figure out how to identify it, measure it, and make decisions if it is worth controlling.
 
#6
How about this.

If that part of the process is 'off' will the line still cycle and process the part to the next position. Error proofing may not be variations of voltage etc., it could just mean the (weld) cycle is skipped and not noticed.
 

Helmut Jilling

Auditor / Consultant
#7
How about this.

If that part of the process is 'off' will the line still cycle and process the part to the next position. Error proofing may not be variations of voltage etc., it could just mean the (weld) cycle is skipped and not noticed.
...simple is better...I agree....
 
V

vanputten

#8
How is verifying a bad part was made "error proofing?" You have not prevented any error. Error proofing prevents errors from happening. Detecting errors already made, in my opinoin, in not error proofing. That might be escape proofing but for sure not error proofing.

In welding, a common error proofing methodology is to create assembly jigs that only allow parts to be welded together in one orientation.

If the electrical system on the welder stop the welder from making a bad part, that may be error proofing.

Regards,

Dirk
 
Q

qwert98

#9
It may just be semantics, but I think what you are referring to is mistake proofing which is the preferred approach where applicable. Error proofing just doesn’t let the error (already made) move on.

I should have kept my question more generic… Suppose you have a process where you push a pin in a hole to a depth of 1 inch. I was considering whatever mechanism controls the press depth (lvdt, encoder etc…) to be the error proofing device. My question was how do we verify that this is working. I think the obvious answer is to under press a part (.9 inches) and make sure it catches it, but what if you can’t intentionally make a bad part? Maybe this is not a proper definition or example of error proofing.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#10
Dirk - escape proofing as you called it is traditionally included in the generic class of "error proof devices" or "mistake proofing" The wording isn't exaclty correct, but it is still calssified that way in most of the literature.

on the other hand the OP's situation isn't so much an error detection device where one could introduce a bad part and see it is detected; nor is it a typical error proofing device where one could try to make an error and see if you coudl create the defect (placing a part in the wrong orientation); it sounds like more of a 'tool control'. (if he really can't vary the voltage and see if the equipment 'shuts down' or 'refuses' to perform the function) he could verify by tracking the performance over time...it's more of a validation but sometimes that's all you can do.
 
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