Visual Inspection Variation - What can we do? Building slot machines

S

sbickley

#1
OK, our assembly lines are stationized assembly stations for building slot machines. A sample station may include harness installation, hardware installation and component installation. The operator does a self check and moves the unit to the next station. That operator (#2) checks #1's work and does their own, etc. At the end of the line is a final inspection/test and QA.

In this type of assembly operation, is it possible to statistically analyze variation and move away from visual inspection. The "variation" between skill levels, training and sheer complexity of the game scare the heck out of me. I.E. we say we are 96% Percent Zero Defects and I'm thinking, no we are probably like 70% PZD if we are lucky.

I can't see how to put a p-chart or control chart in this process to lower the inspection levels. Any thoughts?
 
Elsmar Forum Sponsor
M

M Greenaway

#2
In order to improve the process I would look at what the results from the inspection stages were telling me. Pareto by fault and tackle the biggest issue, i.e. if operator 2 is always correcting a certain wiring harness from operator 1, and this is your biggest issue try to fool proof the assembly process by, for example, making the harness fit one way, or creating visual aids or instrructions for operator 1, or re-training operator 1, etc, etc.

This data capture could be put into an attribute control chart if you wished.
 
S

sbickley

#3
M Greenaway said:
In order to improve the process I would look at what the results from the inspection stages were telling me. Pareto by fault and tackle the biggest issue, i.e. if operator 2 is always correcting a certain wiring harness from operator 1, and this is your biggest issue try to fool proof the assembly process by, for example, making the harness fit one way, or creating visual aids or instrructions for operator 1, or re-training operator 1, etc, etc.

This data capture could be put into an attribute control chart if you wished.
Thanks for the input. That is what I was thinking at this point, I'm not sure if the attribute chart would offer any value or not though, because it is still such a subjective process. We need to standardize training and documentation of results at this point - believe me, still in the dark ages in soe respects. Guess I was fishing for a magic bullet!
 

Jim Wynne

Staff member
Admin
#4
sbickley said:
In this type of assembly operation, is it possible to statistically analyze variation and move away from visual inspection. The "variation" between skill levels, training and sheer complexity of the game scare the heck out of me. I.E. we say we are 96% Percent Zero Defects and I'm thinking, no we are probably like 70% PZD if we are lucky.

I can't see how to put a p-chart or control chart in this process to lower the inspection levels. Any thoughts?
It's not a simple task, but it's probably worth the effort to have a better understanding of the process. The first thing you would need to do is classify defects into general types, then start tracking them at each stage in the process. What you want to know (statistically) is nature of the current process with regard to conformance of output, and how assignable cause variation is significantly affecting it, if at all. Until you have that basic understanding you'll have a difficult time improving anything.
 
Thread starter Similar threads Forum Replies Date
I Overwhelmed with attribute MSA requirement for visual inspection IATF 16949 - Automotive Quality Systems Standard 8
K Visual Inspection Effectiveness Inspection, Prints (Drawings), Testing, Sampling and Related Topics 16
Marc Visual Inspection - Color Vision Coffee Break and Water Cooler Discussions 15
S Need Assistance in Visual Inspection - Tiny electronic components AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
John Predmore What size pinhole can be reliably detected using visual inspection? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
R Can a Attribute Study be considered a Visual Inspection? Reliability Analysis - Predictions, Testing and Standards 6
P Gage R&R on Visual Inspection Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 15
B Gage R & R on Visual Inspection using the Cross Tabulation Method IATF 16949 - Automotive Quality Systems Standard 4
L IATF 16949 7.1.5.1.1 Measurement System Analysis (MSA) - Visual Inspection IATF 16949 - Automotive Quality Systems Standard 14
S Do you use audio-visual streaming during FDA inspection? US Food and Drug Administration (FDA) 3
D Visual Inspection with No Visual Reference General Measurement Device and Calibration Topics 2
N How to reduce RPN of Visual Inspection Process FMEA and Control Plans 6
alonFAI Finished PCB Final Visual Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
N Visual Inspection, Terminology for Process (Tin Soldiering?) Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
G Visual Inspection of Machined Parts - Best Methods Inspection, Prints (Drawings), Testing, Sampling and Related Topics 8
S Visual Inspection Galvanized Attribute Study Quality Tools, Improvement and Analysis 2
A Cosmetic Visual Inspection Specification Advantages Manufacturing and Related Processes 7
A Cosmetic Spec - Convincing Management Visual Inspection Standard is Necessary Manufacturing and Related Processes 5
S FMEA Visual Inspection Detection Rating FMEA and Control Plans 5
G Thoughts on Audit Finding for not doing Gage R and R for Visual Inspection Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 8
J Visual Inspection of Roughness General Measurement Device and Calibration Topics 5
S Gage R&R for Visual Inspection for Sheet Steel Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 6
J MSA for Attribute Visual Inspection Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 3
T Repeated Inspection - Probability of Visual Inspection catching Defects Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
5 Visual Weld Inspection Report - Example needed Manufacturing and Related Processes 3
G Sample Size for 2900 ppm Visual Defects Inspection Requirement Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
J The appropriate Attribute MSA for Automatic Visual Inspection Machine Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 3
S Attribute MSA Visual Inspection Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 4
P Visual Inspection Device for Tiny Rubber Parts General Measurement Device and Calibration Topics 10
B Control Plan Entries - Outgoing Visual Inspection - What should be on a Control Plan? FMEA and Control Plans 18
S High Speed Visual Inspection System vs. Coordinate Machining System Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
I Defectives (ppm) coming from Visual Inspection Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
B Effectiveness of 200% Visual Inspection to Identify Defects and Defectives Inspection, Prints (Drawings), Testing, Sampling and Related Topics 32
B Attribute MSA for Visual Inspection via Camera Automatic Inspection Tool Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
S Visual inspection standards - VDA 16 or Equivalent Inspection, Prints (Drawings), Testing, Sampling and Related Topics 6
T Inspection Method and Control Method for Visual Inspection? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
automoto Visual Inspection of a Weld - MSA (Measurement System Analysis) Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 4
B Visual Inspection (Attribute Data) Gage R&R Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 27
N Tyvek Pouch Seal - Visual Inspection 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 19
Chennaiite High Technology Visual Inspection for Casting and Forging Parts - Zero Defects Inspection, Prints (Drawings), Testing, Sampling and Related Topics 11
A Injection Mold 100% Visual Inspection - Short Shots and Debris not being found Inspection, Prints (Drawings), Testing, Sampling and Related Topics 22
A Ford's requirements for Lumens/Lighting for Visual Inspection Customer and Company Specific Requirements 11
F MSA and Control Plan - Satisfying Visual Inspection Requirements IATF 16949 - Automotive Quality Systems Standard 5
D Visual Inspection - How do you quantify Visual Inspection for TS16949 Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
S Applying ANSI/ASQ Z1.4 given known lot size and 100% visual inspection AQL - Acceptable Quality Level 2
R Visual Inspection Calibration Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
A Visual Inspection Frequency and is there any standard that for visual attributes? AQL - Acceptable Quality Level 2
K Visual inspection and acceptance criteria Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
R Visual Weld inspection training Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
Q PCBA Visual Inspection Tools & Methods - discounting Optical Tools Manufacturing and Related Processes 11

Similar threads

Top Bottom