How to reduce RPN of Visual Inspection Process

#1
Dear all,
I works for a new tire manufacturing company, and there is a visual inspection process to check tire appearance.
For your information, tire appearance defects happen quite frequently, so Occurrence score is high (8~10). However, we use manpower only to check the tire, so Detection score is high to (7~8). Therefore, RPN always higher than 100, but we cannot do any improvement except training and re-training.
So I have 3 questions that need you guys to advice:
1. Is P-FMEA applicable for visual inspection process?
2. Do we have to improve with RPN >100 items for visual inspection process?
3. If we have to improve, what is the suitable way?

Thank you!
 
Elsmar Forum Sponsor
S

sjared

#2
If you haven't done so I would start by ensuring there are inspection standards that the operators can refer to when doing the inspection so they can compare their sample with the standard. I would also be aware of the fact that there are vigilance issues with activities like this. In other words, the operators will not be as effective at catching defects after an extended period of time. Although very technical, the FAA has published guides for visual inspections. Just google "faa guide to visual inspection."
 

Chennaiite

Never-say-die
Trusted Information Resource
#3
1. Is P-FMEA applicable for visual inspection process?
The purpose of Process FMEA is to manage risk in the Manufacturing process. Visual inspection is very much part of Manufacturing process and therefore it is very much part of Process FMEA.

2. Do we have to improve with RPN >100 items for visual inspection process?
There's an excellent article here as to why RPN is meaningless in the first place and then also how it misleads

3. If we have to improve, what is the suitable way?
Generally, the idea is to work on causes of the visual defects (in this case) by setting up a preventive control or at minimum to detect the cause. Now, if you could share little more details on the failure mode, cause, etc, it will be much easier to streamline this discussion.
 
#4
@sjared: Thanks for your information. We have all operation standards, trained properly to all operator with certificating before send them to station. Now I'm checking FAA document.
@Chennaiite: Our failure mode is only "Outflow of defective product" cause by operator cannot find the defect. We apply 200% visual inspection, and another person to sampling check the OK production of every inspector.
 

Chennaiite

Never-say-die
Trusted Information Resource
#5
I assume that defects in discussion are chronic in nature and all necessary steps have been taken to keep the occurrence under control. Some points to ponder are;
- Are you giving adequate time for Visual Inspection?
- Are you maintaining Limit samples?
- Are you keeping your Inspectors on rotation to kill fatigue?
- Is your Inspection area adequately illuminated?
- Did you investigate the cause of outflow whenever it happens?
- Are you isolating defective parts from OK parts?
Last question, did you ever speak to inspectors themselves, particularly from solution point of view?
 
#6
@Chennaiite: please check my respond below:
- Are you giving adequate time for Visual Inspection?
>>> Actually we have fix standard time, but present inspection cycle time is all over standard time. So I can say inspectors have enough time.
- Are you maintaining Limit samples?
>>> No, we have not. I will consider to make some.
- Are you keeping your Inspectors on rotation to kill fatigue?
>>> No, we have not because of shortage manpower. Now continues training more.
- Is your Inspection area adequately illuminated?
>>> Yes, over 3000lux, and monitor monthly.
- Did you investigate the cause of outflow whenever it happens?
>>> Sorry but no.
- Are you isolating defective parts from OK parts?
>>> Yes.
Last question, did you ever speak to inspectors themselves, particularly from solution point of view?
>>> No, I have never.
 
A

antonjav

#7
.... if the pFMEA process that was used is the latest version, which is version 4, you would discover that the the FMEA would be helpful and would naturally give insight as to how visual inspection may be improved.

It looks like that the older version was used ...

Hope that this helps.
 
Thread starter Similar threads Forum Replies Date
A PFMEA (Process FMEA) Detection Rating - Actions to Reduce RPN FMEA and Control Plans 3
adir88 Information of safety can reduce risk now? ISO 14971 - Medical Device Risk Management 12
Ashok sunder Is it possible to reduce Risk likelihood and impact Post control Ranking after corrective action taken for risk? FMEA and Control Plans 1
Ashok sunder Is it possible to reduce FMEA Occurrence and Detection Ranking after corrective action taken for customer complaints? FMEA and Control Plans 6
W Duplicated Gauges want to reduce calibration General Measurement Device and Calibration Topics 2
S Methods to reduce relative humidity in Datacenter IEC 27001 - Information Security Management Systems (ISMS) 3
O How do reduce the risk of suppliers having similar problems? Supplier Quality Assurance and other Supplier Issues 4
R Employee diet to reduce absenteeism and increase productivity Hospitals, Clinics & other Health Care Providers 24
B Proactive efforts to reduce risk - PFMEA risk reduction activities IATF 16949 - Automotive Quality Systems Standard 8
2 High-tech medical equipment to reduce medication errors Medical Information Technology, Medical Software and Health Informatics 5
M Is That Plating Wave Washer will reduce its stiffness? Supplier Quality Assurance and other Supplier Issues 1
corg79 How to Reduce Inspection Frequency in Metal Stamping Company Quality Manager and Management Related Issues 4
C Design of Experiments to Reduce Variation in a Lathe Operation Quality Assurance and Compliance Software Tools and Solutions 9
D How to reduce the number of Quality Inspectors Quality Manager and Management Related Issues 7
S Using ANSI/ASQ Z1.4 to Reduce Impact of Field Service Campaign AQL - Acceptable Quality Level 17
P How to reduce or shut off Compressed Air for Painting Robots Manufacturing and Related Processes 3
P How to Reduce or Eliminate Inspection on an Assembly Line Quality Tools, Improvement and Analysis 10
Sidney Vianna ISO 14006 - New Standard to Reduce Environmental Impacts of Products and Services Miscellaneous Environmental Standards and EMS Related Discussions 1
D How to Reduce Sampling and get the same MTTF (Mean Time to Faliure) Reliability Analysis - Predictions, Testing and Standards 4
J Reduce 50 Work Instructions into 12 Key Processes Process Maps, Process Mapping and Turtle Diagrams 8
A Can we reduce documents checking percentage on supplier certificates? Supplier Quality Assurance and other Supplier Issues 3
T How do I Reduce Frequency of Receiving Inspection Testing for Quality Control Inspection, Prints (Drawings), Testing, Sampling and Related Topics 9
S What to do if no further control possible to reduce the OHS risk? Occupational Health & Safety Management Standards 16
S How to Reduce the Cost of Broken Measurement Equipment Quality Tools, Improvement and Analysis 8
M Plastic Mold Approval - What are the ways to reduce mold approval cycle? Manufacturing and Related Processes 8
A How to Reduce Printed Paper Waste Sustainability, Green Initiatives and Ecology 47
P Does Six Sigma Project have to Reduce Variability? What about a mean shift to target? Six Sigma 6
M Does Disciplinary Action Reduce Operator Errors? Misc. Quality Assurance and Business Systems Related Topics 80
A Control Chart to Track Effectiveness of Actions to Reduce Scrap Rate Six Sigma 7
P Attempting to reduce sample size - The "best" statistical technique to use Statistical Analysis Tools, Techniques and SPC 10
Sidney Vianna ISO Guide 64 will help reduce environmental impacts of products Other ISO and International Standards and European Regulations 1
B On Time Delivery Question - Project to reduce late shipments Lean in Manufacturing and Service Industries 7
T Using SPC Control Charts to Reduce AQL Sample Size AQL - Acceptable Quality Level 16
R CMM Machine upgrade - Ways to reduce CMM inspection cycle time Inspection, Prints (Drawings), Testing, Sampling and Related Topics 5
D Project to Reduce Destructive Sampling in Crimping Process Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
J Customer wants to Reduce GD&T Tolerances on Sheet Metal Subassemblies Manufacturing and Related Processes 8
Y Can I reduce the Sample Size? Sampling check of more than 1,000 pieces daily Inspection, Prints (Drawings), Testing, Sampling and Related Topics 25
Douglas E. Purdy Classification of Suppliers & Control Plans to Reduce Receiving Inspection FMEA and Control Plans 6
R Tool Kits to Reduce Direct Time on Milling Machine Manufacturing and Related Processes 15
D When do you reduce SPC sampling? And How? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
J Cost Down! - Reduce Manpower Misc. Quality Assurance and Business Systems Related Topics 7
R 100% Visual Inspection - Would you Remove or Reduce the Visual Inspection? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 9
S TPM increasing employee overtime costs - How to reduce costs? Quality Tools, Improvement and Analysis 6
A Project to reduce the month end despatch rush Quality Tools, Improvement and Analysis 13
Marc Bye-Bye, Pension! The trend in the US to reduce middle class worker wages World News 17
A PFMEA for many products - How to reduce the number of FMEAs? FMEA and Control Plans 13
T Using DMAIC to reduce equipment downtime Statistical Analysis Tools, Techniques and SPC 1
C Change Management - How can we simplify and reduce our QMS? Misc. Quality Assurance and Business Systems Related Topics 1
Kevin Mader Fear - Deming's Point 8 - Reduce fear throughout the organization Philosophy, Gurus, Innovation and Evolution 30
R Reduce the need for authorisation of low risk changes Document Control Systems, Procedures, Forms and Templates 3

Similar threads

Top Bottom