Is 100% Inspection a Control or does a Process need another type of control?

G

Ghemzie

#1
Hello Experts!

This is my first time to post here, and I appreciate any little information that you could impart for my query.

We have several 100% in-process inspections in the line to capture visual defects and items that are out of electrical specification. Our company required the implementation of FMEA and Control Plan to document our quality process, but we are confused whether a 100% Inspection (Visual or Electrical) is considered as Control or Process.

Is the 100% Inspection considered as a Control or a Process that need another method of control (like sampling inspection from the output of 100% inspection)?

Ghemzie :confused:
 
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A

achorste

#2
Every inspection activity is a control if it's related to the process - however we have to remember that 100% inspection is not 100% effective. To completely (or near as possible) eliminate defects you would have to "error proof" your process to some degree.

The need to extra controls could be identified by your FMEA risk analysis - if the risk of non-conforming product is too high you could justify using other controls on the process.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#3
There are people that like to consider 100% anything part of the process because it occurs to every product. But, anything done to the product to make a decision on the process or product output would be a control. :cool:
 

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#4
Welcome to The Cove! :bigwave:

Inspection, either by sampling or 100%, is not a form of process control. Process control is the activity or set of activities that prevents your items from failing inspection.
 
T

Tom W

#5
Welcome to the Cove!

Like the others have stated 100% inspection for visuals is rarely 100% effective. Is there some other type of defect prevention that could be used? How about concentrating on defect prevention rather than defect detection... can you make the process robust enough to eliminate defects?
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#6
Is the 100% Inspection considered as a Control or a Process that need another method of control (like sampling inspection from the output of 100% inspection)?

Ghemzie :confused:
I guess we should ignore the semantics, which sounds like a good idea at this point, and look at this point of the posting. There is no need to sample a process that already has 100% inspection. When you seeking a failure at a very low frequency, and the the failure is random and not predictable, sampling will never see anything anyway.

It is nice to think that every cause generates clues that it is about to fail. If you can, then great - it is a very rote answer to the issue. But, similar to catching a murderer before he kills, it is not always possible. A random flaw in raw material, for instance, may not be predictable. Sometimes your best bet is to improve your 100% inspection to increase your 80% odds - which is generally attributed to 100% visual inspection. For example, automated inspection has been known to improve those odds. :cool:
 
A

achorste

#7
Inspection, either by sampling or 100%, is not a form of process control. Process control is the activity or set of activities that prevents your items from failing inspection.
That is a good point, but in the case of documenting a control plan it would be considered a control wouldn't it as it is preventing defects from being passed on to the next process / customer?

From what I've seen in the discussion so far I would point the OP towards using the risk assessment to identify potential non-conformances and put the controls in to prevent to occurence & once verified, use an appropriate sample plan to verify the product is conforming. However it is not always that easy and sometimes 100% inspection is the only thing the business will allow ("it's what we've always done" or "it costs too much for the additional equipment") despite the inherent time, quality and cost improvements associated with defect prevention as opposed to detection - I've been there unfortunately.:mad:
 
G

gooofii

#8
Ghemzie , welcome to the cove family:agree:

I agree with Jennifer inspection should not be considered a process control. I believe that the new concept for quality is to eliminate inspection as possible ''Inspect the process not the product''. And as the fellows said to apply mistake proofing , preventive action to eliminate defect . I am just wondering is your product that critical that you do 100% inspection , is the time and money consumed worth doing it...
 

Jim Wynne

Staff member
Admin
#9
Hello Experts!

This is my first time to post here, and I appreciate any little information that you could impart for my query.

We have several 100% in-process inspections in the line to capture visual defects and items that are out of electrical specification. Our company required the implementation of FMEA and Control Plan to document our quality process, but we are confused whether a 100% Inspection (Visual or Electrical) is considered as Control or Process.

Is the 100% Inspection considered as a Control or a Process that need another method of control (like sampling inspection from the output of 100% inspection)?

Ghemzie :confused:
On the AIAG FMEA form, the "Current Process Controls" column is bifurcated into "Prevention" and "Detection" controls, so those who have opined that 100% inspection isn't a process control are not exactly correct. It is a process control from the viewpoint of filling out the form, but as a practical matter it shouldn't be considered process control. Process control is what you do to avoid inspection.
 
G

Ghemzie

#10
Thank you all for the response and viewpoints

Most of our process is done manually, and greatly depending on the skill of the workers that is why it is opted to do 100% visual inspection after critical processes and 100% electrical test to satisfy functional specification.

From the viewpoint of documentation 100% inspection will be considered as Control, but it still necessary to check whether this 100% inspection possibly will create potential failure ( handling that may cause damage or improper setting of the machine) and in this case preventive control should be in placed.
 
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