T
The Fixer
Let me begin saying I am impressed with the expertise exibited in this forum. I am NOT an expert so please utilize KISS principles if you respond.
My company has 21 branches engaged in the repair of printed circuit boards in telecommunications equipment. Long before I got into the quality organization, someone decided that end-item inspection of workmanship, packaging, cosmetics, and functionality using MIL-STD-105 was the way to go.
I think this whole process needs to go ! End-item inspections:
a) attempt to "inspect" quality into the system
b) cause a QC bottleneck
c) waste time with lot resubmittals via rework and reinspection
d) allows technicians to submit substandard work hoping that their units will not be selected as part of the sample.
e) etc., etc., etc.
I am looking for guidelines to perform work-in-progress inspections so quality is built into the system, not retroactively inspected into it. However, 99% of the information in this forum deals with high volume manufactured product. In my business, all the six-sigma, cpK, characteristic curve stuff was performed on the product when it was originally manufactured. We are basically doing rework when the unit fails in the field.
I am having difficuly determining among other things, (with respect to in-process) how to define a "lot" and "sample". Some processes involved are checking the unit in, following a documented repair process for each unit type, affecting repairs in accordance with IPC-610 standards, proper packaging and labeling, modifications, and shipping.It's seems as if I need an almost perpetual internal audit program.
Allowing for my lack of SPC insight, understand that I have the customer's best interests driving this request.
I'm not looking for a system so riddled with data analysis that it negates the time savings I'm trying to gain by eliminating the "extra" process of end-item inspections. Any arrows pointing in the right direction will be greaty appreciated.
My company has 21 branches engaged in the repair of printed circuit boards in telecommunications equipment. Long before I got into the quality organization, someone decided that end-item inspection of workmanship, packaging, cosmetics, and functionality using MIL-STD-105 was the way to go.
I think this whole process needs to go ! End-item inspections:
a) attempt to "inspect" quality into the system
b) cause a QC bottleneck
c) waste time with lot resubmittals via rework and reinspection
d) allows technicians to submit substandard work hoping that their units will not be selected as part of the sample.
e) etc., etc., etc.
I am looking for guidelines to perform work-in-progress inspections so quality is built into the system, not retroactively inspected into it. However, 99% of the information in this forum deals with high volume manufactured product. In my business, all the six-sigma, cpK, characteristic curve stuff was performed on the product when it was originally manufactured. We are basically doing rework when the unit fails in the field.
I am having difficuly determining among other things, (with respect to in-process) how to define a "lot" and "sample". Some processes involved are checking the unit in, following a documented repair process for each unit type, affecting repairs in accordance with IPC-610 standards, proper packaging and labeling, modifications, and shipping.It's seems as if I need an almost perpetual internal audit program.
Allowing for my lack of SPC insight, understand that I have the customer's best interests driving this request.
I'm not looking for a system so riddled with data analysis that it negates the time savings I'm trying to gain by eliminating the "extra" process of end-item inspections. Any arrows pointing in the right direction will be greaty appreciated.