Preventing Set Up Parts from getting in with Finished Goods

[Ajit Basrur]

Paint the Set-up pieces "red" works, in my opinion.

The guys might forget to paint it "RED"

 

[Jim Wynne]

The reasons that this happens are (A) it's easiest for the operator not to worry about it and (B) there are no consequences for violating the process requirements.

Keep in mind that there are often unreasonable demands made of setup people, and they're often expected to violate the laws of physics by being in two (or more) places simultaneously. Because unreasonable promises are made to customers, there's often great pressure on diesetters and other setup people to get the machines up and running. It's easy to overlook the comparatively small stuff if the Sword of Damocles is hanging precariously over your head.

What's needed is a cultural imperative--the idea that stray setup parts are absolute anathema, and whoever sees them laying around is responsible for making sure they don't get shipped to customers. It won't happen without leadership from someone.

 

[larry hopperrath]

Set up procedure as written requires all set up parts to be marked with a yellow paint stick. On 2 occasions over the last 3 days, I have personally witnessed this not being done. I immediately notified our production manager of this (they work for him). I just now came out of a meeting with the set up folks and the production supervisor, basically letting them know that the procedure must be followed or the production supervisor must take some type of action. In my opinion, our setup people are not under the gun to get presses going up and down. I believe the statement about a culture change is accurate.

 

[qcman]

If a part gets to the customer add up what it cost and show it to the powers to be. Money is a great motivator.

 

[Tom Banks]

1)The Set-up process is owned by Production/Manufacturing Process Technicians and verified by Quality.

2)Quality has the responsibility for maintaining these set-up parts to ensure they are meeting the requirements, meaning periodic evaluation/inspection.

3)The Set-Up Manager(Shift/Plant Manager) over all shifts owns the Set-Up Parts.

4) Identify Production/Manufacturing Management Ownership, have these Managers be responsible for maintaining these Set-Up parts in their area and ensure the set-up crew is aware of this change.

5) If you are the boss over the set-up group or this is happening with the Management Owner, document your effort/training to bring awareness, understanding, competence and ensure the proper tools are available for the set-up group to complete their tasks. If all the tools, equipment, materials and ownership along with expectations are defined take appropriate disciplinary action to get back on track.

(Note: The people side is always the last resort, ensure you have all your objective evidence that rules out the process, equipment, material, training, awareness, competency before talking to individuals from a disciplinary approach.)

I hope this helps.......

 

[dannyngky]

We tried spray-painting the parts red immediately when the Supervisor confirmed the parts could not be reworked. We told them the operators the importance of keeping those parts indoors and identified. So far so good!

 

[WSICMM]

The problems of not following procedures not withstanding, we have done the following: (BTW - we are a stamping plant w/ progressive dies)

We had a bunch of large RED covers made to accomodate the bin styles we use. At EVERY break / EVERY coil change / EVERY time the press is not in auto (set-up/adjustment/etc), these covers are placed on top of the bin - that way, if a hit is made...the parts will not make it into the bin...it'll just stay on top of the cover...once a 1st off is complete, the cover is removed and it's regular production.

Also, all of the operators were informed at implementation and there were/are reprocussions for fialing to follow the procedure - that may be the difference...

So far - it has worked well, cheap & easy...

Kind Regards, Aaron

 

[jeffhenry]

Do you have a first piece inspection that the operator, supervisor and quality personel sign off on? If not, maybe thats what you need to eliminate the set up parts being present at first piece inspection. At first piece inspection there should not be any parts in the finished goods container. The operator is more likely to get rid of the bad parts so that quality and his/her supervisor will be out of their work area ASAP!!

I use this procedure now and so far I haven't heard of set up parts making it to my customers. Good Luck and I hope this helps you.