I’ve just read your answers & article about „Red beads”. Of course I agree with all that facts mentioned there but in this case operators are responsible for 100% final control (visual-no other control is possible) and many times they failed. When I observed their job I had an impression that they didn’t put so much effort as they can. This is exactly the problem I try to solve . (Maybe I wasn’t much precise earlier-Sorry about that)
- Have you or any other managers tried pulling a full shift?
(not just a couple of samples, but an entire day of doing exactly the same work under the same conditions - same lunch and break time, etc. - as these folks)
- Do you all have a much better performance rating than the workers?
- If yes, what did you do differently than they did?
- Is their eyesight checked (for free)?
- Did they have adequate breakfast or lunch?
- Were they sleepy?
- Are there distractions which keep them from concentrating on the task at hand? (noise, heat, cold, interruptions, etc.)
- Is there a definite difference in performance between operators? Any idea why?
- If operators fail pieces, do their co-workers in production get penalized?
- When operators do find nonconforming work, does anyone pursue a root cause investigation to find a way to prevent future nonconforming work?
- Are operators paid by the hour or by piece?
Ultimately, if other operators are able to consistently inspect and detect nonconformance, we'd conclude either the original operators didn't grasp the training or that their training was inadequate in evaluating whether they had, indeed, grasped the process of inspection required.
If a new crew performs the job to your satisfaction, replace the old crew with them. Personally, I'd seek a way to salvage the existing crew by mistake proofing the process.