Implementing Operator Product Self-Inspection

qcman

Registered Visitor
#21
I have a layout inspector for each shift that checks part to print and records critical dimensions and or spc. Dimensions to be checked are on the operator work instructions (taken from Control plans) and are recorded on the back of same. As for operator checks they are on the same W.I. and are completed on a 15 minute cycle and also recorded on the back of the W.I. All checks include sample comparision and gage checks.A simple spreadsheet with cells for time,visual check box,gage reading box and whatever else fits the need. Our QS auditors always seemed to like this approuch. Do they ever get fudged? I would have to say yes. The main offense on this is an operator checking off boxes ahead of time to which they say I always do my checks anyway so whats the dif?
 
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sowmya

Involved - Posts
#22
Self inspection is the vital thing to control issues on line. (If it is done really, religiously by production). I dont agree with production operator could not find issues. They are the key people who knows every minute of the product. On the other hand, if they are pressurised for quantity, there are chances that it may skip off. First do it parallely. Find what is the rejection rate by your inspectors after implementing self inspection. Then do it for sampling. Then remove the inspection stage.
 

Jim Wynne

Staff member
Admin
#23
Self inspection is the vital thing to control issues on line. (If it is done really, religiously by production).
No, process control is the vital thing. The amount of inspection being done (by operators or anyone else) is inversely proportional to the amount of confidence in the design of the process. Let the process designers get religion, and we won't have to worry nearly as much about the output.
 
A

aerospaced

#24
Two important elements for delegating quality authority are an individuals integrity and competency. Competency is the easy part - thru training and proficiency tests. Integrity is more challenging. I kept a couple of inspectors busy performing random inpsection audits and providing support to operators.

Some pitfalls to look out for: Operators may be pressured to accept marginal parts by their supervisors who are trying to meet monthly sales targets. If they reject parts or speak up the supervisor will make their life tough.

Lost visibility of rework costs. You will no longer be capturing rework at final inspection, instead operators will most likely be reworking their mistakes before the product moves to the next station. Consider how this cost will be captured in the new system.
 
W

Warburton182

#25
And how can you be certain that inspectors are not recording false results?:mg:
Hey Sal.
Good Point. Inspectors are just as capable of recording false results or trying to hide the fact that they have missed a quality problem that they should have picked up on. Again as Jim said, this is down to fear of being battered for making a mistake. I believe if you've made a mistake, hold your hand up and admit it. It's far better to take a yelling at now than getting the sack for trying to hide it when you are found out.:whip:
 
J

JadeS

#26
I total agree....quality is produced not checked.

This is where the role of quality assurance comes in and as such the quality department becomes a service provider overseeing the Quality Management System.
All quality control functions have to be delegated to the production units. Therefore a training programme has to be made and the necessary training given by competent personnel to ensure that quality control of the process and product are able to be performed by the production units.
A simple structure is as follows.
The production supervisor is responsible for the process's first and last off samples and any non conformities have to be corrected before production release.
After production release ( in process) it is the operators responsibility to inspect to a product control plan/ work instructions the products produced. Records are kept of the measurements (variables and attributes) take every number of hours or units produced, on a works order form with all product parameters. Samples related to this effect are left for the production supervisor to quality control, thereby verification and validation of these samples is performed. Any non conformities have to be reported and segregated through out the whole process. Once the run is completed a last off sample is produced and compared to the first off sample any discrepancies shall be scrutinized and corrected as necessary and the tool/work process preserved for the next run.
Records are kept of,
First off....to include sample and any statements if necessary.
In process quality control results
Last off...to include sample and any statements if necessary
Your comments are well stated. Each of our Operators are responsible for their process from start to finish. This has been implemented for about 7 years. It works basically the same as you have identified.
The Production Supervisors have the overseeing authority. There are a few quality personnel on site as part of the design and engineering groups.

Regards,
Jade
 
L

lukaslukas

#27
Hi,
For past 8 years of watching operators controling their own work I have experienced:
- recording results from never performed measurements (found by audit done by QA eng)
- preparing special samples for measurements (extra careful operation to get good results)
- measuring until 3 good samples are collected > recording only good results > continuing production
- pulling just-out-of-spec measurements into specification
- preparing samples for measurement few days in advance
- building samples from previously selected materials
- not following measurement instructions/frequencies
- and I am sure many other deviations I am not aware of.
The motive is efficiency, material consumption linked bonus and yield linked bonus. Operators try to hide problems for their short term benefits.

Please consider this and implement preventive measures before you implement self-control. These can be:
- regular audits by independent (non production bonus driven) QA people
- regular quality awareness trainings
- discipline actions for people who intentionally do not follow clear rules
- I have lately implemented Control Plan measurements to be done by Quality Inspectors for 4 weeks in one production line. I will collect the data and compare with what operators recorded previously. I am going to analyze collected data and decide what to do further (extensive training for production and re-implement self-control, implement Quality Inspectors for other production lines).
 
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