Visual Inspection of Machined Parts - Best Methods

G

GRISHAG

#1
From time to time we have customer complaints due to lack of visual inspection of our products (machining parts).
Do you can give me tips regarding correct way of this simple, but important activity?
 
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Stijloor

Staff member
Super Moderator
#2
Re: Visual inspection.

Can you be a little more specific?

What product characteristics must be visually inspected?
 
G

GRISHAG

#3
Compliance of part/assembly to model/drawing, the product must be free of scratches, dents, all items in batch have to uniform, etc (inspection is performed by quality control personnel without using of measuring equipment)
 

ScottK

Not out of the crisis
Staff member
Super Moderator
#4
Still need more to go on.

If somone told me a cause was "lack of visual inspection" my reply would be "start doing visual inspection".
 

Proud Liberal

Quite Involved in Discussions
#5
To determine the repeatability of the process, perform an attribute GR&R. You can also send rabbits down the line and see if they get caught.
 

John Broomfield

Staff member
Super Moderator
#6
From time to time we have customer complaints due to lack of visual inspection of our products (machining parts).
Do you can give me tips regarding correct way of this simple, but important activity?
GRISHAG,

Customers don't want more inspection. They want parts free of nonconformity.

Inspection is not the way to produce parts free of nonconformity. Prevention and single piece flow can result in parts free of nonconformity.

Or is the customer asking for conforming parts to be free of blemishes? That would be a contract change.

John
 
G

GRISHAG

#7
Thank you for your response.
I want to clarify: we do our best to prevent failures during production process, but we're obligated to perform the final inspection of our products in order to prevent shipping of nonconforming items. There are methods and tehniques for performing visusal inspection, specially, if there are some items in production batch. For example, first step is checking compliance of first item in batch to drawing. There are additional steps which give high confidence that customer will not receive nonconforming parts after final inspection. Can somebody give tips for this?
 

John Broomfield

Staff member
Super Moderator
#8
Thank you for your response.
I want to clarify: we do our best to prevent failures during production process, but we're obligated to perform the final inspection of our products in order to prevent shipping of nonconforming items. There are methods and tehniques for performing visusal inspection, specially, if there are some items in production batch. For example, first step is checking compliance of first item in batch to drawing. There are additional steps which give high confidence that customer will not receive nonconforming parts after final inspection. Can somebody give tips for this?
GRISHAG,

FAI from a capable production process makes some sense to me but not when the first article is from an incapable process.

Just as the best visual inspection of the output from incapable production processes makes little sense to me.

Why is your production process resulting in nonconforming product? I suggest that is the problem to solve.

Investing in creating a world class inspection process may draw precious resources away from improving the production process itself.

John
 
I

iamtroll

#9
Depending on the level of cosmetic defects that your customer is asking you to address, I would look at the quality of the lighting in both your production area and your inspection area. Also, you may want to investigate magnifying your visual inspection. In order to examine parts post plating, we use 5x-7x binocular magnification. This generally helps us to get below the customer threshold of cosmetic issues. The Mantis Compact by Vision Engineering is our go to device. It is expensive but it does the job for inspectors who do close to 8 hours of visual inspection. Here is a link to their site.
http://www.visioneng.us/products/stereo-microscopes/mantis-compact-visual-inspection-microscope

For a less pricy binocular inspection device, you can try AmScope devices that are also working for us.

http://www.amscope.com/lowpower-stereo-binocular.html?gclid=CL6bl_nUsL4CFcNj7AodV3wAQA

I hope that this helps.
 
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