How to Fix Mis-Identified Dimensionally Identical Parts

Golfman25

Trusted Information Resource
#1
Say you have two parts: A and B. They are dimensionally identical, except say part B has a hole (and part A does not). In fact, you run all part A's and when you need B's you take a few A's and turn them into B's. So at any one time, you have a bunch of A's in process and a bunch of B's in process. Both are adequately identified on/in their containers and go thru QA without issue.

Then they get to packaging. During packaging, when transitioning from Part A to B, the person packaging them mistakenly identifies a single box (of 11 total boxes) as part B when it is really part A. It is easy to do, because your eye tells you they are the "same" part.

It is very rare. May happen once in several years. Back in the day we would call it a "brain fart" and move on. Today, the world is going to end and you have to go thru the 8D process. Any thoughts on the best way to fix? Thanks in advance.
 
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howste

Thaumaturge
Super Moderator
#2
If part B has a hole that part A doesn't have, what's the difference in weight between part A and part B?
 

Miner

Forum Moderator
Staff member
Admin
#5
Why not just make part B's?
This is a good suggestion if part B will fulfill all of the functional requirements of part A.

If not, I had similar situation with right hand vs. left hand parts where the differences were very subtle. We used color coding on all documents, visual aids that exaggerated the differences between the two, and most effectively packed and labeled online at the final operation. The operator scanned a bar code on the visual aid that printed the exact number of labels needed on demand. There was a lot of discipline involved such as only having paperwork for the product run, clearing the line between runs, etc., but it did work.
 

Golfman25

Trusted Information Resource
#6
Have to make both parts. Not really our call.

And the parts are make from. So you take 100 As and pierce the hole to make Bs. They have there own documentation, containers, etc.

We just had someone packaging them that wrote the wrong number because they are so similar.
 
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