Azaarus
Starting to get Involved
Quality Supervisor for automotive plastic injection molding here. Last week we had an IATF surveillance audit. All in all the audit went well, and we walked away with two minors (one in maintenance and one in quality). I am having a very hard time with trying to come up with a corrective action for the quality hit.
Here is the long story: I have been hounding on my quality team about inspection documentation since I started here in early 2020. I have been asking them to write EVERYTHING down on their in process inspection sheets, including down time, process adjustments, issues, high scrap, visual defects... basically everything. No one was listening. Finally, after I was reviewing the inspection sheets I found that everyone was writing OOT numbers for our coating measurements, not documenting it, not having a supervisor sign off, and not documenting adjustments or additional shots that were checked after adjustments and I lost it. I wrote EVERYONE in the department up. This was about a month ago. They started getting better, but still not doing what I asked, and it came back to bite us.
Jump to last Monday. IATF auditor is here, doing his thing. He was looking over the inspection sheet that was being used at the time, and he pointed out that there were OOT measurements written down. They were signed off by the supervisor, so I know the inspector told the supervisor the numbers were low... but noting else beyond that was documented. No one wrote down that an adjustment was made or that another shot was checked after the adjustment. No notes were written about the adjustment, what was done with the parts to ensure no defects escaped, the timing, how many other parts were checked after, etc. So, we got hit for inadequate inspection documentation and traceability. I 100% agree that we deserved that hit, especially since it has been an ongoing issue for so long.
My problem now is that I can't think of adequate corrective and preventive actions other than retraining and verifying inspection documentation in real time (which I really don't have time for). I don't think it is a systemic issue at all, because we have multiple work instructions on proper procedures and documentation processes for inspection and reaction to non-conforming product, the team has been adequately trained, and they know what they are supposed to be doing, they just don't do it. Can someone, ANYONE, please give me some guidance with this?
Here is the long story: I have been hounding on my quality team about inspection documentation since I started here in early 2020. I have been asking them to write EVERYTHING down on their in process inspection sheets, including down time, process adjustments, issues, high scrap, visual defects... basically everything. No one was listening. Finally, after I was reviewing the inspection sheets I found that everyone was writing OOT numbers for our coating measurements, not documenting it, not having a supervisor sign off, and not documenting adjustments or additional shots that were checked after adjustments and I lost it. I wrote EVERYONE in the department up. This was about a month ago. They started getting better, but still not doing what I asked, and it came back to bite us.
Jump to last Monday. IATF auditor is here, doing his thing. He was looking over the inspection sheet that was being used at the time, and he pointed out that there were OOT measurements written down. They were signed off by the supervisor, so I know the inspector told the supervisor the numbers were low... but noting else beyond that was documented. No one wrote down that an adjustment was made or that another shot was checked after the adjustment. No notes were written about the adjustment, what was done with the parts to ensure no defects escaped, the timing, how many other parts were checked after, etc. So, we got hit for inadequate inspection documentation and traceability. I 100% agree that we deserved that hit, especially since it has been an ongoing issue for so long.
My problem now is that I can't think of adequate corrective and preventive actions other than retraining and verifying inspection documentation in real time (which I really don't have time for). I don't think it is a systemic issue at all, because we have multiple work instructions on proper procedures and documentation processes for inspection and reaction to non-conforming product, the team has been adequately trained, and they know what they are supposed to be doing, they just don't do it. Can someone, ANYONE, please give me some guidance with this?
