Setup Verification in IATF 16949 Clause 8.5.1.3

Peters

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#1
I know that there were several discussions about setup verification in this forum.
But we (me and my friends-auditors) have discussion connected with translation problems of the IATF 16949 text.

My question:
Is "setup verification" connected only with the control/measurement of the first piece (with correction - if needed) like in QS-9000 definition, or there are other forms/methods of implementation of the "setup verification"? First of all I would like to know what the author has in mind in this text.

In our discussion there are some other ideas like setup parameters instruction, setup parameters records... but I can't see this in IATF 16949 requirements.

What do you think?
 
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QualitySpirit

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#3
Hello, I think the intention of set up verification is to verify that after the process is re-set it is still producing acceptable parts within specification.

In many cases, I have seen it is not the measurement of the "first" piece.

For examples, in plastic injection molding I often see - after they change the mold, flush the old material. They have to inject almost 100 shots until they find the setup is ok e.g. without short shots, appearance issues, abnormal weight. The shots injected before this acceptable piece then go to scrap. So in this case, it is not the first piece measurement.

Set up verification in my opinion is whatever action that they do to make sure the set-up is OK - and it needs to include output verification such as product inspection/measurement/tests not only verification of inputs e.g. setup parameters.
 

Peters

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#4
For examples, in plastic injection molding I often see - after they change the mold, flush the old material. They have to inject almost 100 shots until they find the setup is ok e.g. without short shots, appearance issues, abnormal weight.
"until they find the setup is ok e.g. without short shots, appearance issues, abnormal weight" - But still check of the product is set-up verification. It's not strictly the first piece, it's longer series, but the quality of the outgoing product confirms: set-up is correct.
A similar situation is in the production of wire or flexible shafts - acceptable first series of this product will be typical setup verification. Am I right?
 
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QualitySpirit

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#5
"until they find the setup is ok e.g. without short shots, appearance issues, abnormal weight" - But still check of the product is set-up verification. It's not strictly the first piece, it's longer series, but the quality of the outgoing product confirms: set-up is correct.
A similar situation is in the production of wire or flexible shafts - acceptable first series of this product will be typical setup verification. Am I right?
Hi, I have been to both automotive electrical wires and cold drawn shafts manufacturing sites myself.

As the product has to be extruded very quickly through the length, usually they have diameter sensors online that check in real time and they adjust parameters such as speed until the diameter is in a controlled range. It would be a big waste if they wait until it finishes a whole roll then do the verification.

I think job-setup in this case is when all diameter sensors along the length show green signals.:caution:
 

Peters

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#6
I remember the flexible shaft production - shortly after the start, process is stopped, setter cut 1m of the product and check the product parameters. And then next start after product checking and results confirmation.
 

QualitySpirit

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#7
I remember the flexible shaft production - shortly after the start, process is stopped, setter cut 1m of the product and check the product parameters. And then next start after product checking and results confirmation.
OK - I will remember to look at it again next time I visit. :thanx:
 
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