Starting In-Process Quality Inspection in the Production Shopfloor

R

Rafierce

#1
Dear All

Im from QA/QC department, planing to implement an In-Process quality inspection at my company's production shopfloor. But i got no experience at all.

What i have done till now - visited every section to understand the problems they have now trying to think of ways to do in-process inspection using the solutions to the problems above. I'm kinda stuck here.

Production has its own In-process inspection (not done by QA/QC).

Can anyone guide me along? Thanks :D


Cheers
Rafe :D
 
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S

sam_ck

#2
For my IPQC daily practise, all the inspection checklist are basically based on the quality plan in my company. I think you are in a ISO certified company, your company should have the quality plan. You can refer to the SOP and base on the QP, you can generate the IPQC checklist and perform IPQC task daily.
 
R

Rafierce

#3
Yes, im in an ISO certified company. But, my company doenst have SOP. Thats why i will need to come out a rough plan for all In-process. Is abit hard to start.

Please help. Thanks.
 
U

Umang Vidyarthi

#4
Dear All

Im from QA/QC department, planing to implement an In-Process quality inspection at my company's production shopfloor. But i got no experience at all.

What i have done till now - visited every section to understand the problems they have now trying to think of ways to do in-process inspection using the solutions to the problems above. I'm kinda stuck here.

Production has its own In-process inspection (not done by QA/QC).

Can anyone guide me along? Thanks :D


Cheers
Rafe :D
Since production has the 'In-process inspection' aka 'Patrolling inspection', why do you want the Q/A also to do the same. Do you feel that the IPI conducted by production is insufficient inefficient or ineffective? If so, then improve it in stead of creating a super check. Quality control is part & parcel of production department, they are supposed to produce quality product.

Experience dictates that, whenever you impose a quality controller above production people, the fight between the two ensues instantly and quality deteriorates.

If you feel that the IPI conducted by production is not effective, then you may increase the frequency. In my company one patrolling inspector covers eight work stations with a periodicity of 45 minutes. The Q/A conducts only final inspection before despatch.

Hope this helps

Umang :D
 
R

Rafierce

#5
Hi Umang

Thanks for the reply.

I do think the production has insufficient IPI as the control has not been tight enough to tackle on quality issues. (Dont even talk about reducing waste)

Experienced workers will be a challenge if IPI by QC inspectors on them.

How does your company make sure one patrolling inspector covers eight work stations with a periodicity of 45 minutes? This is efficient!! :)
So his job is more of sampling inspection? What are the things they look into while performing inspections? Mind to share? Thanks

Thanks :D

Rafe :D
 
U

Umang Vidyarthi

#6
Hi Umang

Thanks for the reply.

I do think the production has insufficient IPI as the control has not been tight enough to tackle on quality issues. (Dont even talk about reducing waste)

Experienced workers will be a challenge if IPI by QC inspectors on them.

How does your company make sure one patrolling inspector covers eight work stations with a periodicity of 45 minutes? This is efficient!! :)
So his job is more of sampling inspection? What are the things they look into while performing inspections? Mind to share? Thanks

Thanks :D

Rafe :D
The patrolling inspector spends about four minutes on each work station, in which he checks 3 to 5 pieces on each station (depending upon the number of specs.). Now, if a machine produces 100 components in 45 minutes then 3% to 5% on-spot inspection is carried out at every stage of component being developed. (The frequency may be decreased or increased, in accordance with process being in-control or out-of-control.)

2. The inspectors check all the specs. mentioned in the Work instruction sheet and or in Process Flow Diagram. Each inspector carries a Process inspection sheet, mounted on a clip board. At the upper end is the M/C no., Operator, Part no. etcetra. Below we have columns giving specs to be checked and then five columns to record actual readings, followed by remarks column.

Hope this helps

Umang :D
 
R

ram4302

#7
Dear Mr.Rafe,

Pl. understand and collect CTQ (Critical to Quality ) characteristics for all products.You can define this in control plan and start inprocess check.
 
R

Rafierce

#8
Dear Ram

Thanks for the information. Characteristics have to be defined to find out the processes involved. From there, quality can be controlled..
 
R

Rafierce

#9
The patrolling inspector spends about four minutes on each work station, in which he checks 3 to 5 pieces on each station (depending upon the number of specs.). Now, if a machine produces 100 components in 45 minutes then 3% to 5% on-spot inspection is carried out at every stage of component being developed. (The frequency may be decreased or increased, in accordance with process being in-control or out-of-control.)

2. The inspectors check all the specs. mentioned in the Work instruction sheet and or in Process Flow Diagram. Each inspector carries a Process inspection sheet, mounted on a clip board. At the upper end is the M/C no., Operator, Part no. etcetra. Below we have columns giving specs to be checked and then five columns to record actual readings, followed by remarks column.

Hope this helps

Umang :D

Dear Umang

Looks like the inspector has to be displined enough to carry the IPI. :D
So we are talking about Sampling check in this case.

The inspection criteria has to be defined in the inspection check sheets in order to faciliate the checking process.

Will start working on this in process inspection. Thanks :D

Rafe :D
 
U

Umang Vidyarthi

#10
Dear Umang

Looks like the inspector has to be displined enough to carry the IPI. :D
So we are talking about Sampling check in this case.

The inspection criteria has to be defined in the inspection check sheets in order to faciliate the checking process.

Will start working on this in process inspection. Thanks :D

Rafe :D
U R welcome Rafierce. :bigwave:

Umang :D
 
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