Setup Part Management - Preventing Escape


I'm quality manager for a company from automotive. My biggest problem is that aprox 75% of the claims that I received are set up parts from CNC machining( mostly turning) , even if I have 100% control on production line after ( parts just skip control).
Can anyone help with a solution about how to identify and stop set up parts and how to make 100% control on production line more effective ( without implementing firewall after the line ) ?
Thank you very much.


If your CNC programmer is worth his salt, he should be able to put a conditional in the code. So if the machine is in setup mode, it makes an extra identification cut. If you were leak testing, you'd put his across a seal so it would be rejected. OR you could face the height below the lower limit and get them with a simple poka yoke. When not in setup mode, the cut is not made.


If you do 1st off inspection surely this will catch the rejects, the inspector just quarantines all parts made prior to 1st off that meets the specification of drawing. We have a similiar problem and the inspector now collects all parts on machine bench that do not meet drawing requirement and quarantines them.

Project Man

Involved In Discussions
We did two things to address this exact issue:
1. Physical - We have clearly labeled, color coded bins at the work centers for non-conforming parts. Parts are placed in the bin, by the operator, as soon as they are found non-conforming.
2. Systematic - Every employee electronically enters good and N/C in our system at the end of each shift. A tag is printed to identify the N/C product and it is placed in a separate area for supervisor review and follows a completely separate track than the conforming parts from that point on.


Quality Manager
Do you mean that 75% of all your known scrap is from setup parts? Are you trying to find a way to reduce setup part scrap?


75% of the claims from my customers came because set up parts where delivered to client. I'm trying to find a method to properly stop set up parts when they appear and detect them in my workshop.


It is common practice at my shop that before every new run or set up, the machine is completely cleared of all parts and chips that may contain parts. All set up parts are scrapped before going into production. It sounds like your machinist may be loosing parts within the machine during the set up process and is too lazy to find/remove them before production begins, or that the loading of new material is not working properly. The later would give you a half machined part that may resemble a set up part with every new bar loaded. Without 100% screening, those parts may slip past your sample lot inspection and ship to the customer. I only work on Swiss CNC's, so that is my Swiss CNC analysis.


If it happens again have the operator responsible for setting up and running the machine visit the customer to explain what happened.


Quality Manager
When I think setup part I think of the part used to set up a machine for a job run that usually becomes the first good first part of that order, it can sometimes become a scrapped part for various reasons. Is that what you mean?

What do you mean when you say you have "100% control on production line after"? Do you mean you have 100% dimensional inspections on every part or something?
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