CarolX said:
Marc,
Here's what we do.......
Any parts produced during the set-up of the machine are marked with a yellow paint pen like this
s/u
to identify it as a part produced during set-up. Frequently, we can use these parts for set-up at additional operations (i.e. a formed part from the brake can be used to set-up the spot welder).
I assume the operator is packing set-up pieces, correct?
This is what I'm being told by several managers and a QE there. Believe it or not I suggested this yesterday (day 1) - but was thinking of the machine marking the parts until the setup was complete because I don't trust operators in this setting to mark the pieces.
I'm still investigating the process. Only been there 2 days - but, it's a place I set up the quality system for in 1991-2 so things have changed a lot - but as you know, some things seem to never change. I was looking over the problems and talking to the folks and I keep hearing our favourite phrase
Operator Error . The managers are telling me that they go through the setup and (they believe...) that this is what is happening.
That said, it's been a labour intensive effort company for a long time. QS-9000 now and all that rot. I have seen they have taken a lot of hand work out since 1991 and have put in a lot of robots. I sorta feel silly as I sit there and listen to the managers speak about what's going on and you sorta follow, but then I end up as Columbo and finding possible errors in where they're tossing the blame.
I am just starting to review nonconformance trends and such but wanted to start some minds thinking. And... I admit I was a bit hasty in asking - they had just gotten my computer hooked up and I had to go through heck and high water to get internet access but it wwas turned on and I wanted to see that I could access the forums and post without firewall problems.
That said, I'm not a metal stamping expert and although these folks have been doing this for years (metal forming) I want to jump out of their paradigm by hearing from folks here as I investigate problems and try to provide solutions. They have excellent training programs, but, as we all know, sitting at a press all day does not draw the most enthusiastic employees.
Anyway - this is my first 'information fishing trip'. I'm supposed to be at this place most days for a month or two or three (Know whut I mean, Vern?) so it could get interesting. I'm knee deep in Requests for Corrective Actions. Man - it really HURTS to be on this side of the fence. It's darn near work!
I'll provide more details as I get them to try to narrow this down. I'll review the specific process tomorrow and come back with more details. The bottom line to me is it appears most of this will require poka yoke to reduce (I will never say Eliminate - I'm too old and know better...) the possibility of human error.
I am also interested in hearing from others in an effort to benchmark 'Industry Standards' as soon as I have enough parameters to define the processes (they don't do deep draw, for example, and they do a lot of punching with secondary operations like trim after punch. But - I'll start a thread on that soon.<hr>By the way, for those of you who are Harley fans, the place does the stamping, polishing and silk screening for one of their new, fancy bikes - a V Rod or something (I'm really gonna look to see what model that bike is tomorrow). It's a tear drop, polished aluminum alloy with HARLEY-DAVIDSON silk screened on the metal. Goes over where the gas tank would be between ones legs. The bike in the poster I saw there reminds me of the DeLorean - lots of polished metal, only this is an aluminum alloy instead of SS.
No - I can't sneak one out so don't even ask.