Hardness inspection Audit Finding Employee error

J Allen

Involved In Discussions
#1
During a recent audit, the auditor witnessed our inspector performing hardness inspection using a brinnel portable tester. There is a requirement that the load duration time will be at least 10 to 15 seconds. My inspector waited only 6 seconds. After being issued a finding, I began the root cause investigation. Our procedure clearly calls out the requirement. The employee was trained to the procedure. When asked why, he shrugged his shoulders with a response of "I don't know," yet he told me he was aware of the requirement and that he "counted" too fast. This is a case where the inspector failed to perform the inspection per the procedure and not a case of lack of training. AS9100 now requires to take human factors into consideration.
I plan to do re-enforcement training and perhaps add at note to the inspection record to wait 15 seconds.
What is a reasonable root cause?
 
Elsmar Forum Sponsor

Bev D

Heretical Statistician
Staff member
Super Moderator
#4
The cause was simple - humans are not accurate timing devices. We either ‘count’ time too quickly or too slowly. The solution to this is to add an accurate timing device. This may be manually triggered (cheaper) by the inspector OR it can be incorporated into the testing device to automatically trigger at the initiation of the test (or process) and complete the test (or process) at the end of hte proscribed time (this is more expensive especially if it must be added to the test device after purchase but it is more robust to human error)

Writing requirements into a procedure is not a very robust solution to anything. Teaching the ‘why’ of a requirement and utilizing mistake proofing concepts is far more robust...
 

Eredhel

Quality Manager
#5
When I was inspecting quench times for in house heat treat I had a digital stop watch as well as a wall clock. I'm guessing you just need something similar.
 

QuinnM

Starting to get Involved
#6
Hi J Allen,

As stated above the root cause is noted. What I will add, is the idea that the timing device get incorporated into the brinnel portable tester. I know nothing about this tester, so I do not know if possible, but having the 10 to 15 seconds automatically controlled would be your desired option.

Quinn
 

John Broomfield

Staff member
Super Moderator
#7
During a recent audit, the auditor witnessed our inspector performing hardness inspection using a brinnel portable tester. There is a requirement that the load duration time will be at least 10 to 15 seconds. My inspector waited only 6 seconds. After being issued a finding, I began the root cause investigation. Our procedure clearly calls out the requirement. The employee was trained to the procedure. When asked why, he shrugged his shoulders with a response of "I don't know," yet he told me he was aware of the requirement and that he "counted" too fast. This is a case where the inspector failed to perform the inspection per the procedure and not a case of lack of training. AS9100 now requires to take human factors into consideration.
I plan to do re-enforcement training and perhaps add at note to the inspection record to wait 15 seconds.
What is a reasonable root cause?
J Allen,

Root cause:

Failure of the organization to provide a timing device and to ensure it is used.

You could ask why again, but what’s the point of blaming the manager you now want to sign the P.O.?

John
 
Thread starter Similar threads Forum Replies Date
J Hardness Inspection Test - Rockwell in Lieu of Brinell General Measurement Device and Calibration Topics 6
M Proper terms for describing Hardness General Measurement Device and Calibration Topics 5
S GR&R for Hardness Tester and Arc Spark Spectrometer Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 15
S Portable Magnetic Hardness Testers - Aerospace Manufacturing and Related Processes 4
P Very cheap Hardness Blocks unfortunately without Traceability General Measurement Device and Calibration Topics 11
C Hardness Testing - Low Cpk's using Minitab Misc. Quality Assurance and Business Systems Related Topics 10
O Hardness Testing and Certifying Product AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 6
kedarg6500 How much test force to be applied for Vickers hardness Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
L Hardness Testing - Rockwell 15T Scale Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
K Wilson Hardness Tester Model 525 Accuracy/Repeatability issues help General Measurement Device and Calibration Topics 4
Johnnymo62 What oil do I use for our Starrett 3814 Hardness Tester? General Measurement Device and Calibration Topics 1
kedarg6500 CA111-SAE Copper Washer Hardness Measurement Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
W MSA on a Hardness Tester to satisfy a Customer who is requiring Hardness Cpk Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 17
Geoff Cotton Measurement Uncertainty (MU) of HR-150A Rockwell Hardness Tester Measurement Uncertainty (MU) 1
N Verifying Calibration of Hardness Gauge vs Actually Calibrating It General Measurement Device and Calibration Topics 2
M MSA - What method should we use for the stability of hardness? Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 1
S ASTM Standard for Hardness Spec for 6063 T6 Aluminum Extrusions Various Other Specifications, Standards, and related Requirements 1
Q Definition Rockwell Hardness definitions - BW 96 Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 3
V What should I require of a Heat Treat PPAP? Surface Hardness per SAE J664 APQP and PPAP 1
J Hardness Testing E error requirement, Why? Various Other Specifications, Standards, and related Requirements 4
J Requirements for Hardness of Metrology Instrument Parts General Measurement Device and Calibration Topics 3
Ron Rompen Recommended Rockwell 30T Scale Hardness Tester to verify Incoming Product General Measurement Device and Calibration Topics 1
G Hoffman Scratch Hardness Test - General Parameters for Pass/Fail (Paint Coatings) Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
W Cpk for Hardness - PPAP rejected due to no Cpk value being given for a hardness FMEA and Control Plans 10
Ron Rompen Affri MetalTest Portable Hardness Tester Review General Measurement Device and Calibration Topics 1
C MSA for Hardness Machine and Tensile/Compressive Machine Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 3
J Any Difference Between Bench Top and Portable Hardness Tester? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
J Rockwell Hardness Testing Question Inspection, Prints (Drawings), Testing, Sampling and Related Topics 9
somashekar Information sharing: Week 22, 2010 (HARDNESS, THREADS, BEARINGS) The Reading Room 3
Q Calibration of Hardness Tester ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 12
Ron Rompen HV Hardness Testing Conversions - CRA 1070, tempered 440-520 HV10 Various Other Specifications, Standards, and related Requirements 2
J Sources of Potential Measurement Variation for Brinell Hardness Test Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 4
A Difficulties in performing MSA on Rockwell Hardness Tester Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 20
A Cause and Effect Analysis - Hardness of Rubber (i.e., durometer) Quality Tools, Improvement and Analysis 11
B Certifying our house for Hardness and Conductivity Testing General Measurement Device and Calibration Topics 8
I Are there any Procedures or Standard relating to Retesting of Hardness of bolts? Quality Manager and Management Related Issues 5
C Specification (hardness) for stainless steel SUS 310 3/4 Hard Manufacturing and Related Processes 3
A Calibration of Rockwell Hardness Tester IATF 16949 - Automotive Quality Systems Standard 10
P Micro Hardness Tester Gage R&R Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 6
K Rockwell Hardness Testers ? Brand Recommendation Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
B Expiration Date for Standardized Rockwell Hardness Blocks Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
ScottK Portable Hardness Testing and Testers for Incoming Bar Stock Testing Inspection, Prints (Drawings), Testing, Sampling and Related Topics 8
K Certifying Existing Hardness Tester Indenters / Penetrators General Measurement Device and Calibration Topics 9
kedarg6500 Potential Failure Mode - Mix Charge for Hardness - Casting Process FMEA and Control Plans 1
E Units of Measure for Case Hardness such as HV, HRB, HRC, etc. Various Other Specifications, Standards, and related Requirements 7
J How to calibrate Hardness Rockwell, Brinnell & Vickers Tester machine General Measurement Device and Calibration Topics 5
J What Hardness for .090 Thick Silicone Bronze, Extra Hard Temper (cda 65500-h06) Manufacturing and Related Processes 5
B Portable hardness testing recommendations - Upper Rockwell B scale Inspection, Prints (Drawings), Testing, Sampling and Related Topics 6
D Is the ''K'' in the Knoop hardness test pronounced or is it silent? General Measurement Device and Calibration Topics 17
C Standard hardness test procedures for ASTM-E18-03 Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4

Similar threads

Top Bottom