How effective is 100% inspection

A

Andrews

#11
Thanks everyone for your response.


Is there no way at all to improve effectiveness (i.e no defective pieces escape) of 100% inspection? how about changing the inspectors once in an hour ?
 
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P

Phil P

#12
Hi Andrews,

Changing the inspectors on an hourly basis will reduce the effects of fatigue, but that's about all. The effectiveness of 100% inspection will be dictated by the accuracy and repeatability of the inspection process.
 
E

e006823

#13
Andrews said:
Thanks everyone for your response.


Is there no way at all to improve effectiveness (i.e no defective pieces escape) of 100% inspection? how about changing the inspectors once in an hour ?

How are you currently inspecting for this defect?
 

Jim Wynne

Staff member
Admin
#14
Andrews said:
Thanks everyone for your response.


Is there no way at all to improve effectiveness (i.e no defective pieces escape) of 100% inspection? how about changing the inspectors once in an hour ?
Andrews,
Everyone here wants to help, but it seems that you haven't gotten the message so far. Every inspection process is different. Not only is every inspection process different, but each process might be different each time it's run due to the nature and interactions of the variables involved. If you think that operator fatigue might be a factor that needs control, then by all means act accordingly. Perhaps, in some instances, fixed gages might help, or better lighting or better training...
Sometimes inspection processes can be improved, and sometimes they are what they are and nothing can be done about it. You have to evaluate each instance individually and make the best decision you can, then check to see if your decision was correct or not, and make adjustments if necessary. Plan, do, check, act.
 
R

Rob Nix

#15
You might also consider what the biggest bang for your buck will be. At some point, the cost to control (i.e. inspect) the products will end up higher than the costs associated with the risk of missing a few bad parts (look up information on alpha and beta risk). In other words, you may be expending a lot of costly effort beating a dead horse. On the other hand, if even a few defects cause a serious risk to the business, you must look into preventive controls - not more inspection.
 
C

Craig H.

#16
Andrews said:
Thanks everyone for your response.


Is there no way at all to improve effectiveness (i.e no defective pieces escape) of 100% inspection? how about changing the inspectors once in an hour ?

If this is a visual inspection, changing inspectors will likely INCREASE variability, unless there has been very specific training covering what is and is not a defect.
 
Q

qualitygoddess - 2010

#17
Andrews said:
100% inspection is for a diameter 15.87/ 15.83. The cause for defect in this characteristic is plating thickness variation on this component.
About the only thing I can add to the posts that have already been written -- I still don't think we know how you are inspecting, but I suspect by hand gauge. This looks like a pretty tight spec, so should you be investigating an inspection method that is more automatic? I think that was mentioned in one post for a special fixture, etc. Programmable CMM's might be able to improve the inspection repeatability. However, there are a whole list of potential issues with these devices.........and it might be too expensive. You'll never get to 100%. You have to construct a process that produces to a certain sigma for the process steps.

It's time to go back to the process and be very thorough in reviewing the process and its capability to produce to spec. Dust off that FMEA and get going!

--QG
 
D

David Hartman

#18
qualitygoddess said:
Programmable CMM's might be able to improve the inspection repeatability. However, there are a whole list of potential issues with these devices.........and it might be too expensive.
You could consider a articulated arm/portable CMM (Romer, FARO, etc.). I just purchased a 4ft. Romer Infinite arm for less than $50k and that includes an off-site 2 day training course for 2 people.

You'll never get to 100%. You have to construct a process that produces to a certain sigma for the process steps.

It's time to go back to the process and be very thorough in reviewing the process and its capability to produce to spec. Dust off that FMEA and get going!

--QG
This is so true! Much more needs to happen besides the "inspection" efforts. Poka-Yoking the process to minimize/eliminate the process variations should be of greater priority than the inspection efforts (greater bang for your buck).
 
R

Randy Stewart

#19
What kind of plating is being applied, is that an OD or an ID dimension, and what spec is the part being plated to?. Most zinc plating call outs are only 12 - 20 microns and most paints are somewhere around 25 microns max, so I can't see that as being a big factor in your failure rate. However, if you are talking tube nut dimensions this is a different set of circumstances. Not only must you be concerned about the OD & ID but you must calculate the affects of the threads, you may be looking at an engineering change request.

Most plating thicknesses are measured by using the eddy current method. The reported thickness is an average of 10 readings. The easiest way to ensure accurate measurments is to use a raw/unplated part to zero your scope with. Let me know if I can help.
 
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