Looking for important points regarding First Piece Inspection

Azaarus

Registered
#1
Quality Control Supervisor for IATF / ISO certified automotive plastic injection molding facility here, and I am looking for some resources regarding first piece inspection. A bit of backstory, today my first shift quality inspector brought me two different signed off and tagged first pieces (one made by the second shift quality inspector yesterday afternoon and one made by the third shift quality inspector this morning). One of the first pieces has a cracked tab, and the other has a short shot. This is unacceptable.

I want to put together a training sheet to recap the importance of performing a complete and thorough first piece inspection. I listed the most important key reasons for performing a first piece inspection such as identifying issues early in the run, verifying the process is correct, verifying part dimensions are correct, verifying visual compliance, having a point of reference for the operators, etc. as well as including the QMS work instruction and procedure for first piece inspection, but I am having a VERY hard time finding resources online regarding the importance of first piece inspection, what to do and what not to do, and effective verification methods.

Can anyone point me in the right direction so I can gather some more items to include in my training document? I'm looking for something IATF / ISO / QMS oriented, if possible. I have the key points covered, I just want to dig a little deeper, but Google isn't helpful (I learned to search for "first piece..." instead of "first shot..." because I kept getting results for Covid vaccines :cautious:). Any help is appreciated, because my brain is toast today!
 
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John Predmore

Trusted Information Resource
#2
Welcome to Elsmar.
One place you can search is the search function of the Elsmar site: first article . Try different terms people might use, such as PPAP, FAIR, layout inspection. first piece, and so on.
 

Miner

Forum Moderator
Staff member
Admin
#3
All processes have dominant sources of variation as shown below. An injection molding process is dominated primarily by setup, tooling and material. A good first-piece inspection is a typical control for setup and tooling because, if the first piece is good then all subsequent pieces may be assumed to be good as well (assuming the process is capable) provided the setup is not changed and the tooling does not become damaged. Additional checks may be necessary at material changes. The converse of this is that if the first part is bad, then the subsequent parts have a high probability of being bad as well. That is about as important as it gets.
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Ninja

Looking for Reality
Trusted Information Resource
#4
Sounds like the biggest "Aha" moment needed is that First Article Inspection requires the first part to actually be OK before proceeding...

If you have the time before delivery is required...I would have the supers and the QA person who signed off do a 300pc random inspection of the lots in question...outside of any other remediation you do to ensure good product.

Knowing is good, but a recognizable slap drives it in a litter deeper...(Got that from Mr. Miagi on The Karate Kid).
Note that this will not increase your standing with them...so check that area first...
 

Azaarus

Registered
#5
Sounds like the biggest "Aha" moment needed is that First Article Inspection requires the first part to actually be OK before proceeding...

If you have the time before delivery is required...I would have the supers and the QA person who signed off do a 300pc random inspection of the lots in question...outside of any other remediation you do to ensure good product.

Knowing is good, but a recognizable slap drives it in a litter deeper...(Got that from Mr. Miagi on The Karate Kid).
Note that this will not increase your standing with them...so check that area first...
I had all parts from both runs placed on hold for sort. The QAs that made the bad first pieces will be the ones to sort them. Luckily there were only 7 boxes of the short shot before it was caught, but I have 2 skids of parts with cracked tabs in my hold cage. Thanks for the reply!
 

Azaarus

Registered
#6
Welcome to Elsmar.
One place you can search is the search function of the Elsmar site: first article. Try different terms people might use, such as PPAP, FAIR, layout inspection. first piece, and so on.
Thanks for replying. Yeah, the first thing I did after Google was searched the Elsmar Cove Forums. I have never posted here but I often come here and usually find some really great answers and resources. I just couldn't find exactly what I was looking for. I actually did read the post you linked yesterday.
 

Azaarus

Registered
#7
The converse of this is that if the first part is bad, then the subsequent parts have a high probability of being bad as well. That is about as important as it gets.
Yep... this sums it up. Sure enough, we found short shots packed (I haven't looked at the 2 skids of cracked tabs yet). I put everything for both parts on hold for 100% sort. Luckily, the part with the short was only 7 boxes. The other one was 2 skids... that are currently sitting in my hold cage!
 
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