Incoming Inspection Skip Lot - Industrial staples

J

juliov

#1
Quality pros need your wise advice and opinion,

we receive many different types of industrial staples for bedding and automotive, various types of nails, pneumatic application tools are used for the application.

We don't have too many issues with nonconforming incoming quality, thus, inspecting every single lot everytime they come in would be wasteful time, especially if some of the staples and nails never had a nonconformance. Still our manager wants them to be checked all the time. Can we show him a plan of inspection that would cover lot incoming testing, or sampling plan in order to keep good product, while inspecting only when is needed. Skip lot info let me know.

Comments, can you guys send an attachment doc with the test plan?
 
Elsmar Forum Sponsor

Jim Wynne

Staff member
Admin
#2
Quality pros need your wise advice and opinion,

we receive many different types of industrial staples for bedding and automotive, various types of nails, pneumatic application tools are used for the application.

We don't have too many issues with nonconforming incoming quality, thus, inspecting every single lot everytime they come in would be wasteful time, especially if some of the staples and nails never had a nonconformance. Still our manager wants them to be checked all the time. Can we show him a plan of inspection that would cover lot incoming testing, or sampling plan in order to keep good product, while inspecting only when is needed. Skip lot info let me know.

Comments, can you guys send an attachment doc with the test plan?
I don't have any sort of document for you, but I do know that the best way to approach this situation in most cases is by showing the manager the money. If you can determine how much needless incoming inspection costs your company, and how those costs can be reduced or eliminated, you're much more likely to get management's attention. If someone thinks that an inspection process is necessary, the only real way to convince them otherwise is to show them the money flying out the window.
 
J

juliov

#3
Really good answer. Thanks.
While we are on this topic, what factors would be considered to determine the quality cost to the incoming inspection. Ex hours spent inspecting, salary, doing the setup for the application tools, what is your opinion, what other factors can be included in this type of cost analysis?
thanks,
 

Jim Wynne

Staff member
Admin
#4
Really good answer. Thanks.
While we are on this topic, what factors would be considered to determine the quality cost to the incoming inspection. Ex hours spent inspecting, salary, doing the setup for the application tools, what is your opinion, what other factors can be included in this type of cost analysis?
thanks,
It's best--and simplest--to deal with direct costs such as wages/hours, and to include some suggestions for redeploying inspectors (to jobs where they can do some good) rather than just laying people off. The approach should be showing management a good way to save some money, rather than just eliminating what management perceives to be an important function.
 

Coury Ferguson

Moderator here to help
Staff member
Super Moderator
#5
I have moved this post to this forum, since it is regarding Skip Lot Inspection... It should get more responses.
 
R

ralphsulser

#6
There are a couple other methods I have used.
1-If you can't eliminate the incoming inspection then use reduced sampling. I think it is described in the old MIL-STD-105. You inspect 10 consecutive lots at normal sample size-example such as 150 per lot. If all 10 lots are acceptable then you can switch to reduced sample sizes such as 50 or 25 per lot. But if you find any nonconforming samples you then revert back to the original sample size of 150 per lot.
2- Dock to stock. Again if you get 10 consecutive acceptable lots and normal sample size, then put the supplier on "dock to stock". This means the product bypasses incoming inspection and goes directly to production stock.
If non conformances are found during production, then revert to normal sample sizes until another 10 lots are acceptable.
 
B

Britman - 2012

#7
Are these nails, industrial staples etc, "off the shelf", if so I would class them as a "commodity item" possibility widely available, stable manufacturing processes and use by many other companies, therefore inspection would be complete many times and any batch / feedback problems would be passed to the supplier for corrective actions, for these items "skip lot" would be acceptable and "value adding".

I have in the pass used MIL-STD 105 as commented by ralphsuler, a good system, however, the system currently available is BS6001 - I have attached a summary review completed a few years ago in my present company - could help as a start.(QAP are procedures).

I found if you can place your incoming goods into 3 headings - Commodity, Leverage and Process / Product Critical, you can target the level of inspection / supplier monitoring.

Leverage - Suppliers hold a negotiating advantage with your company - therefore the supplier will be monitored through a SQA program

Product Critical - Strategic importance to the functionality of Product
Process Critical - Strategic importance to the build Process of Product e.g. "Bottlenecks" - therefore the Supplier and company must have a common advantage to supply correctly each and every time.

Commodity - Components widely available and priced comparatively low

Leverage and Process / Product Critical goods will need customer / supplier relationships and understanding - in some instances "supplier support programs", however if its a Commodity item, with no failure history, use "skip lot" or "dock to stock" systems
 

Attachments

Helmut Jilling

Auditor / Consultant
#8
There is no requirement to do incoming inspection per se. The requirement is to have a means to determine whether incoming product meets spec (ISO cl 7.4.3). Incoming inspection is only one way of many to do this.

When I buy a box of nails, if one is bent, I throw it away. If the box has many, I take it back to Home Depot. But I am not going to do a sample process of each incoming box of nails.

For my system that is adequate. For other systems, you might need to do more. But, make sure the end justifies the means. There are many ways to do it.
 

Douglas E. Purdy

Quite Involved in Discussions
#9
There are a couple other methods I have used.
1-If you can't eliminate the incoming inspection then use reduced sampling. I think it is described in the old MIL-STD-105. You inspect 10 consecutive lots at normal sample size-example such as 150 per lot. If all 10 lots are acceptable then you can switch to reduced sample sizes such as 50 or 25 per lot. But if you find any nonconforming samples you then revert back to the original sample size of 150 per lot.
2- Dock to stock. Again if you get 10 consecutive acceptable lots and normal sample size, then put the supplier on "dock to stock". This means the product bypasses incoming inspection and goes directly to production stock.
If non conformances are found during production, then revert to normal sample sizes until another 10 lots are acceptable.
I forgot what industries you are involved with, but was wondering how your control plans showed the tranisitioning from an Inspection Frequency to a Dock-To-Stock. Do you just reference a procedure that identifies this transition, if so then how does the Customer know that this inspection transition is part and parcel to the Control Plan?

Thanks,
Doug
 
R

ralphsulser

#10
The MIL-STD-105D for normal and reduced sampling plan system I referred to in the above post was previously used at a different company supplying government, commercial, and tier 2 automotive products.

Unless your customer specifies otherwise about sampling of incoming products, then I think you could issue a procedure for Incoming Inspection Sampling and define your own sampling plan steps, or reference the MIL-STD-105D if still available.

You could define this in your columns of the Control plan headings of Sample size, Frequency, Control Method, and Reaction Plan.

At the current company we are a tier 1 to Ford, Honda, and Suzuki and not currently using this because we have incoming sampling size plans initially established by our corporate quality staff . The sample sizes are designated by letter codes on the control plans. We change the process and final parts sampling as needed for our systems. Our incoming inspection for the automotive parts is only steel bars, and we inspect and document every lot for dimensional and chemical analysis certification supplied with each shipment.
 
Thread starter Similar threads Forum Replies Date
J Incoming Inspection Records using Excel File ISO 13485:2016 - Medical Device Quality Management Systems 2
J Requirements as a Distributor for Incoming Inspection of Purchased Finished Medical Device Medical Device Related Regulations 0
J Action Not defined in procedure - NC - Incoming inspection AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 1
silentmonkey How to decide what characteristics need to be verified during incoming inspection? ISO 13485:2016 - Medical Device Quality Management Systems 5
D Incoming (Receiving) Inspection - General form for incoming part inspection Document Control Systems, Procedures, Forms and Templates 17
T Primary & Secondary Inspection Definitions - Incoming, In-process & Final Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
Ajit Basrur Incoming Inspection for Instructions for Use (IFU) 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 1
R Is pre-conditioning supplier component before incoming inspection tests allowed? Quality Manager and Management Related Issues 16
T How to identify requirements for 'Incoming inspection' Inspection, Prints (Drawings), Testing, Sampling and Related Topics 5
J Incoming Inspection Plans under Design Control (part of DMR)? 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 4
L How to define R & D Receiving (Incoming) Inspection Plan Design and Development of Products and Processes 18
M Incoming, In-Process, Final and Outgoing Quality Inspection Procedure examples Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
M Partial Incoming (Receiving) Inspection Delivery Inspection. Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
C Incoming Inspection Database Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
C Incoming Inspection Acceptance Sampling by Variables and Minitab Quality Tools, Improvement and Analysis 1
S Calibration/Certification requirements for an Incoming Inspection Fixture Inspection, Prints (Drawings), Testing, Sampling and Related Topics 8
M Incoming (Receiving) Inspection Procedure - Please Review Supplier Quality Assurance and other Supplier Issues 7
K Incoming (Receiving) Inspection for Commodity Items used in Medical Devices ISO 13485:2016 - Medical Device Quality Management Systems 11
C Medical Device On The Floor Receiving (Incoming) Quality Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
S Inspection & Verificaton of Incoming Material - How best one can accomplish ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 20
R Incoming Inspection, Handling and Storage Procedure for Lead Acid Batteries Other Medical Device and Orthopedic Related Topics 1
T Is Material Certification Required for Incoming Material (Receiving) Inspection? Supplier Quality Assurance and other Supplier Issues 10
J Incoming Inspection AQL Sampling of Bulk Textiles AQL - Acceptable Quality Level 3
N How to apply Incoming (Receiving) Inspection to Customer Supplied Material? IATF 16949 - Automotive Quality Systems Standard 18
L Critical Characteristics in Incoming (Receiving) Inspection - Inspection Levels Inspection, Prints (Drawings), Testing, Sampling and Related Topics 18
P Implement FAI process in my Incoming (Receiving) Inspection Procedure ISO 13485:2016 - Medical Device Quality Management Systems 6
S Incoming Receiving Inspection from Sister Plant IATF 16949 - Automotive Quality Systems Standard 7
M Incoming Quality Receiving Inspection Report sample Supplier Quality Assurance and other Supplier Issues 2
S Incoming Goods Process Flowchart for Inspection - Rejection / Approval example Lean in Manufacturing and Service Industries 8
M Incoming (Receiving) Inspection of SMT components Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
T Which control chart for incoming (receiving) inspection - Sample size of 10 Inspection, Prints (Drawings), Testing, Sampling and Related Topics 9
K Incoming Materials First Article Inspection (FAI) Procedure needed Document Control Systems, Procedures, Forms and Templates 2
S OPL (Open Point List) in audit - Incoming inspection result Inspection, Prints (Drawings), Testing, Sampling and Related Topics 15
L Certificate of Conformity? Supplier incoming material inspection CE Marking (Conformité Européene) / CB Scheme 3
J Auditing Incoming Materials (Store) - No Procedures nor Inspection carried out. Misc. Quality Assurance and Business Systems Related Topics 10
H Medical Device Manufacturer: Incoming Raw Material Inspection ISO 13485:2016 - Medical Device Quality Management Systems 5
W Identifying Critical Components for Incoming Inspection ISO 13485:2016 - Medical Device Quality Management Systems 27
H Incoming Inspection Sampling Plan ISO 2859-1/ ISO 2859-2 Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
C Incoming Inspection - Consignment Storage of some Purchased Parts Supplier Quality Assurance and other Supplier Issues 4
G Ball Grid Array (BGA) component Incoming Inspection IPC-7095 Various Other Specifications, Standards, and related Requirements 3
G IPC-Std-610D Component Incoming (Receiving) Visual Inspection Various Other Specifications, Standards, and related Requirements 16
K Incoming Receiving Inspection Form Document Control Systems, Procedures, Forms and Templates 6
T I would like to implement ISO 2859 standard for Incoming (Receiving) Inspection Other ISO and International Standards and European Regulations 3
E Should we do Incoming Inspection (Receiving Inspection)? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 14
Q Streamlining incoming audit - 2 separate inspection processes Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
Z How to handle Incoming (Receiving) Inspection as a PFMEA item? FMEA and Control Plans 36
T Return to Vendor processes - Supplier parts which fail incoming inspection Supplier Quality Assurance and other Supplier Issues 5
I Incoming parts inspection in automotive industry Inspection, Prints (Drawings), Testing, Sampling and Related Topics 11
M Incoming Inspection Procedure - Seeking an example Document Control Systems, Procedures, Forms and Templates 11
B Process FMEA Scope - Does PFMEA cover Incoming (Receiving) Inspection & Dock Audit? FMEA and Control Plans 8

Similar threads

Top Bottom