Incoming Metal Coil Inspections - How many do you inspect?

B

Bob_M

#1
FYI: We're ISO 9001:2000 supplying finished stamped metal parts to trucking industry and sheet metal a/c parts to mobile home industry.

We/I currently inspect all incoming coils, strips, and metal sheets used in production prior to releasing to warehouse/pressroom.

Currently I inspect thickness and width (and length) for a minimum of ONE coil per skid, regardless of number of skids or number of different heats we receive.

Many years ago (back when we had problems with steel suppliers), EACH coils was inspected.

Historically (~5 years) we've had less than a dozen material problems that were caught/catchable during incoming inspections. So supplier & material quality is not a "major" concern.

Recently, it was suggested that I begin to limit my inspection to 1 random coil per HEAT. (Recently moved a job back in-house and we might get 15+ skids per steel shipment 1 or twice a month).

Based on our suppliers' and material history, I don't have a major problem inspecting ONE coil per HEAT regardless of the number of skids received. However I didn't want to jump the gun without some other opinions (positve and negative).

FYI: Operators are required to check thickness of each coil when they start to use them as well has regular in-process checks as required per part.

Let me know what you think.
Thanks Bob
 
Elsmar Forum Sponsor
R

ralphsulser

#2
Do you have history on the variable results of your previous incomong inspection results? History of rejection rates of coil sizes by supplier? Maybe you could go to skip lot inspection, or establish a dock to stock program if you have historical data showing a certain number of lot receive with no defects or rejections. Also can you use CPk or PPM to establish frequency?
What is a typical length of a coil, and how do you check it?
Just curious because when I was in the metal stamping of body panels, those coils were real big, and no way were we going to roll them out to measure length.
 
D

dbulak

#3
Good supplier

A good supplier will furnish representative samples as well as SPC documentation for width and gauge. I know this can be done. Therefore, after a certain peroid of doing some checking of the suppliers product you will not have to check every coil or for that matter any coils.
 
B

Bob_M

#4
I don't have any statistical data, but I've been the Quality Mgr for nearly 3 years, 2 years as Product Engineer and nearly 10 years total. (BTW we probably still have about 10+ years worth of incoming material inspections/certs still on file/in boxes).

In the last 3 years I think we've rejected less than 5 shipments. Most of them were for EXCESSIVE crossbow/camber/cracking (drawn parts).

Thickness/Width issues are extremely rare from our suppliers. (0.018 - 0.250 coils and strips).

In the past 10 years our VP/Purchaser has probably rejected less than a dozen shipment for quality/size issues.

I COULD go Dock-to-Stock. We already have that for other products/supplies.
 
R

RosieA

#5
For all the reasons Bob stated, my company has also gone Dock to Stock.

There are very few steel rejections. Having said that, I'm not producing product for the automotive industry either!
 

CarolX

Super Moderator
Super Moderator
#6
Bob_M said:
I COULD go Dock-to-Stock. We already have that for other products/supplies.
So...why don't you? If your operators are already verifying material gage and type, the other issues you have you really won't see on the coil whe the material comes in, will you.

Dock to stock it!!!
 
B

Bob_M

#7
CarolX said:
So...why don't you? If your operators are already verifying material gage and type, the other issues you have you really won't see on the coil whe the material comes in, will you.

Dock to stock it!!!
Quote from "What about Bob" - Baby steps, Baby steps, Baby steps... I'm Sailing! I'm Sailing! :biglaugh:

(Typically operators verify thickness and sometimes width - Incoming inspections are still there to catch the rare problem BEFORE it gets to production so we can re-order replacement material ASAP).
 
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
M Material incoming to the production process reflected in PFMEA FMEA and Control Plans 9
silentmonkey How to decide what characteristics need to be verified during incoming inspection? ISO 13485:2016 - Medical Device Quality Management Systems 5
I Incoming insepction needs repair - sell as "new", "brand new", or something else Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
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
C ISO13485 Incoming Receiving Parts Verification ISO 13485:2016 - Medical Device Quality Management Systems 13
T Can incoming and outgoing areas be allocated inside the store? Other ISO and International Standards and European Regulations 1
R Policy Statement for FDA CFR 820 Acceptance Activities of Incoming Products. Other US Medical Device Regulations 1
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
A Incoming Material Quality Assurance Cell Document Control Systems, Procedures, Forms and Templates 4
R PFMEA (process FMEA) for Incoming Material stage FMEA and Control Plans 7
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
T Incorporating incoming procedures (ISO9001:2008) with ISO 13485:2003 Supplier Quality Assurance and other Supplier Issues 3
S IQC (Incoming Quality Control) requirement on Electric Power Adaptor for US and CE Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
M Incoming (Receiving) Inspection Procedure - Please Review Supplier Quality Assurance and other Supplier Issues 7
Q Current Process Controls (Prevention) and Incoming Raw Material Inspections FMEA and Control Plans 8
K LEAN in the Incoming/Receiving Department Lean in Manufacturing and Service Industries 9
M Incoming Source of Variation & Source of Variation in Process Flow Chart IATF 16949 - Automotive Quality Systems Standard 3
F Supplier Measurements vs. Incoming (Receiving) Measurements Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 16
K Incoming (Receiving) Inspection for Commodity Items used in Medical Devices ISO 13485:2016 - Medical Device Quality Management Systems 11
Ron Rompen Recommended Rockwell 30T Scale Hardness Tester to verify Incoming Product General Measurement Device and Calibration Topics 1
C Medical Device On The Floor Receiving (Incoming) Quality Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
B Sample Size for Incoming (Receiving) Materials and Parts Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
T Incoming (Receiving) Quality Control Laboratory for Raw Paper Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
S Inspection & Verificaton of Incoming Material - How best one can accomplish ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 20
P Incoming (Receiving) Components Inspections Pharmaceuticals (21 CFR Part 210, 21 CFR Part 211 and related Regulations) 1
R Incoming Inspection, Handling and Storage Procedure for Lead Acid Batteries Other Medical Device and Orthopedic Related Topics 1
T Incoming Testing for Non-Woven Materials used for Pharma Products and Cosmetics Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
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
Q Control plans for Incoming, Warehouse and Shipping process FMEA and Control Plans 5
N How to apply Incoming (Receiving) Inspection to Customer Supplied Material? IATF 16949 - Automotive Quality Systems Standard 18
C What to look for when inspecting incoming packaging goods such as empty retail boxes Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
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
D Samples from Lots of Incoming Raw Materials - Sampling Protocol Help Inspection, Prints (Drawings), Testing, Sampling and Related Topics 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

Similar threads

Top Bottom