Traceability System to trace Failed Product for Corrective Action

[Coury Ferguson]

my goodness, how do you all know sooooo much

This is the best forum to get information for a Quality Professional. We have many talented people here.

 

[Moncia]

Ohhh I know
I have been reading your posts for a year now. Got many good ideas from you guys. I just never posted anything before

 

[Coury Ferguson]

Ohhh I know
I have been reading your posts for a year now. Got many good ideas from you guys. I just never posted anything before

Thanks for the compliment on the Cove, Moncia.

Ask as many questions you wish. We are here to help.

 

[Moncia]

OOOhhhhhh I will
trust me
Thank you

 

[Michael T]

Re: Your current system

we keep track of lot number which roll was used to die cut the circles from. that is stamped on the traveler
the problem I have, I cannot trace a faulty product to the person within the production in the case of complaint-to do the corrective action properly

When conducting root cause analysis, it is best to look at the process first... what in the process allowed the operator to make the mistake? If one person can do it, then they all can do it. So... the corrective action is to correct the process utilizing your quality tools like poke-yoke, kanban or some other more appropriate tool.

Have you looked at utilizing Ishikawa (Fishbone) diagrams to determine potential causes of the error and then examining each of those causes to find the root cause? That might help also.

Unfortunately, the real difficulty comes in when you examine the process and the process is robust, yet, people still make mistakes. Then it comes down to an individual level. But this should be the last resort.

Hope this helps!!

Cheers!

Michael

 

[prabhatchaddha]

Re: Your current system

For traceability best way would be to use a bar code system integrated with the ERP system.

for this you can have as following.

1. Traceability has to be maintained through raw material to the finished product.
2. Bar code system which is applied through out the manufacturing process from receiving to finish good.
3. Incoming material is bar coded at the time of receiving and all issues from store and in between must be controlled through the barcode/ERP system.( when ever the output is created a new sticker is printed having new barcode for input we need to scan the barcode of sticker on the input roll)
4. at every stage of production a barcode sticker has to be printed and WIP is moved into the next stage/Department/Section
5. The bar code sticker is put on each and every packed material Box/Roll.
6. In case of complaint each roll the traceability is done through the sticker on box or roll which contain all the relevant detail.
7. IN case sticker can be retained from the complaint box then simple scanning can get u all the relevant detail from raw material to process.

Regards

 

[prabhatchaddha]

Re: Your current system

monica this system certainly requires cost. You can also maintain them in computer in excel sheet or in manual register.
With barcode system your time in making and retrieving will be saved a lot and changes of error will be negligent.

Regards

 

[Moncia]

Re: Your current system

There is no way my boss will spend a penny to purchase bar code system
but thanks for the advice

 

[David Hartman]

Re: Your current system

Monika, I will assume that the die cuts are done on a machine and that you have multiple machines. If this is correct track the machine and time/day that the product was cut, and track separately the operator assigned to the individual machines and the time/day they worked at that machine (this is something a supervisor could do). This should provide you with traceability back to a machine/process and you should be able to then tie that to a specific operator. If my assumptions are incorrect, I apologize.