Setup Part Management - Preventing Escape

[dubrizo]

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

What about not doing this (as much as I wish we could have operators face the music) hahaha. It's possible the operator is doing exactly what he/she has been told to do... Not only that, but this method does not identify and correct the root cause of the issue in order to prevent the release of further non-conforming product to the customer.

To the OP - I'd say if you haven't done so already, open a Corrective Action and really get to the root of the issue. This is especially valid if you're ISO certified. Section 8.7.1 of the 2015 standard states: "The organization shall ensure that outputs that do not conform to their requirements are identified and controlled to prevent their unintended use or delivery.

Just my .

 

[AeroSteve]

We have struggled with this in the past too. One simple update to our QMS that has helped us is:

When we find that a part is scrap, (assuming we are holding the part when we find out) we Literally do not set the part down until we mutilate the part.

So for example, the operator is using a micrometer to inspect a diameter and finds it to be undersize, before he sets it down, he walks over to the bench vise and smashes the part, or to the the saw and cuts it in half, etc.

It hasn't solved all our problems in this area, but this has helped.

 

[weakness]

You can create an instruction first ... (3,5,7)parts will seperate and will check detailed after production by only one operator.
Keep in quarantine area (until production finished)
This is different from %100 because one operator can controlled sensetively.
And seperation is ideal solution for this kind of parts.
You can choose best operator from MSA .

 

[ISOCOP]

Yes bar ends can be misconstrued as nonconforming setup parts. We require the operators to bring all nonconforming setup parts to QA along with the first article submission.