MSA (Attribute Gage R&R) on our process monitoring points

S

Swagg - 2009

#1
I've been ask to create a MSA on our process monitoring points.

Each process produces something, and we have ask the down stream process to monitor the up stream quality. This is all attribute data since we are a distribution center. Management doesn't feel all defects are being recorded and they have ask me to perform a gage R&R.

Our gage is the operator and each process has 5 to 8 characteristics. i.e. Receiving produces a pallet of finished goods ready to be stocked that is properly placarded, correct product, correct qty & undamaged.
Due to the high volume of work, I have found it difficult to have different operators measure the same item since we are computer driven I can get a do over on a pallet for the next operator to process the same pallet.


Any suggestions?
 
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T

Tom W

#2
Swagg said:
I've been ask to create a MSA on our process monitoring points.

Each process produces something, and we have ask the down stream process to monitor the up stream quality. This is all attribute data since we are a distribution center. Management doesn't feel all defects are being recorded and they have ask me to perform a gage R&R.

Our gage is the operator and each process has 5 to 8 characteristics. i.e. Receiving produces a pallet of finished goods ready to be stocked that is properly placarded, correct product, correct qty & undamaged.
Due to the high volume of work, I have found it difficult to have different operators measure the same item since we are computer driven I can get a do over on a pallet for the next operator to process the same pallet.


Any suggestions?
What you are describing sounds to me like you want to do a "Dock Audit" on the product. In other words you want to ensure that it is correct at the appropriate sage of the process. I think you might be better off trying to do some type of pareto analysis on the issues (nonconformances) that are discovered then complete some type of root cause analysis on the "big hitters" and try to eliminate the problems. I have attached a form we use for documenting the dock audits that we do. You might get some ideas from this. Hope this helped.
 

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S

Swagg - 2009

#3
Tom,
You are somewhat correct.
I have five primary processes, Receiving, Product Movement, Picking, Verification & Shipping.

Our Receiving process is to ensure that when they mark the pallet as ready to be putaway it is the correct product, has the correct placard, is not damaged etc... the monitoring point is for the next process step(product movment) to check that the above was correct when they picked up the pallet.(Hence, how well did receiving do their job) The same applies to all processes. The concern is that the next process may not be recording all findings. (Example: No process recorded any "Damaged" finding last month, however the Inventory department had several adjustments due to damage)
I can not say what process failed in recording the damaged, because I don't know where it occured)

This is a new way of thinking here as we have only implemented process monitoring for the past 3 months.

History:
We created flow charts for each process.
We defined what each process produces.
We created process monitoring data collection form / database
We trained each employee in their area of what to check.(examples included)
Started collecting data.
 
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