Sampling Plan for Final Inspection and Process Verification

Bev D

Heretical Statistician
Staff member
Super Moderator
#21
OK this isn't an AQL inspection no matter what you or anyone else calls it.
This is simply an in process inspection that does minimize the amount of rescreening should a defect be found. It also helps minimize the amount of scrap or rework for systematic failures where all product has a defect due to a machine failure (for example). It's may be a smart plan (although without further detailsl of the process and what can go wrong I can't say for sure). It is definitely too large a sample size although the frequency isn't bad. I would probably go with 5 to 10. But not an AQL type which is really intended for 'randomly' occurring defects. This can be statistically justified to an auditor as well since it makes common sense.

However, for any kind of real release plan that is based on the ANSI standard you need TO START WITH WHAT AQL YOU NEED. Then you select your confidence level if different from the standard of 95%. Then you select your sample size based on the lot size for the AQL and confidence level.

What AQL do you want? Remember that the AQL is the defect rate that you will accept 95% of the time if it is present. You cannot have a 0% defect rate...
 
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M

Murphys Law

#22
I'd step back and look at the bigger picture and question if the test is value added or not. This is an ideal use of a SPC chart.

What has been the trend on your pull tests. Had it always passed ? Is the pull test automated with a reading such as gF or is it just pass/fail.

If you've never had failures, then you should question the validity of doing this test. You could go to a periodic monitor instead of a regular sample test.

Alternatively you could also use the test more predictively in instances where operation required assistance or was down for maintenance.

If you are getting rejects, then your sample plan needs to be based on your acceptable quality level that you wish to ship. You should also be looking at a screening method if you are getting failures above your quality targets. You can also use paretos to get to root cause to fix or at least understand / contain the problem.
 
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