What to Check - Set Up vs. In Process Inspections

Golfman25

Trusted Information Resource
#1
So we are debating reworking our inspection criteria. Trying to come up with something workable but robust. So here goes:

Assume each part we make starts off with a First Article Inspection - a complete dimensional layout, including notes. Usually done before production, when the tooling to make the part is made and approved. Very comprehensive. We are good with that.

Next is a setup inspection. Tooling is setup and the initial samples are approved to run. This is where we are struggling/debating. How comprehensive should our inspection be? Whole print, just the "important" dimensions we'll check during production, or something in between?

Then we have regular old in process inspection. We have this down reasonably well. We check those dimensions which are critical, important or otherwise subject to variation during the run.

And Final, mirrors the in process inspection.

Looking for any thoughts, approaches, etc. Thanks in advance.
 
Elsmar Forum Sponsor

Michael_M

Trusted Information Resource
#3
One of the problems we have during setup inspection and in-process inspection is not the critical dimensions or the tight tolerance dimensions, the operators check these frequently. We have problems with dimensions (such as chamfers and Radi) that are ±.010 because they are such open tolerances people do not check them. Typically when they are found, it turns out to be a full days productions or more.

To combat this, and yes, it seems like combat, we require in-process inspection on open tolerances as well tight tolerances, just not as frequent.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#4
It really depends on your Customer, how they feel about the dimensions, features and properties that are specified but are not noted as critical or important and how much risk you are willing to tolerate.

A very well characterized set of tooling and processes (operator, equipment and environment) and materials reduces the need for inspection...

Without understanding the above, the only I can offer is uninformed opinion.
 

Golfman25

Trusted Information Resource
#5
One of the problems we have during setup inspection and in-process inspection is not the critical dimensions or the tight tolerance dimensions, the operators check these frequently. We have problems with dimensions (such as chamfers and Radi) that are ±.010 because they are such open tolerances people do not check them. Typically when they are found, it turns out to be a full days productions or more.

To combat this, and yes, it seems like combat, we require in-process inspection on open tolerances as well tight tolerances, just not as frequent.
That's similar to the issue we face. Usually there are a few dimensions which aren't all that important and are difficult to check -- you may have to cut parts, etc. If we do that for every setup (especially for a few hundred parts), it can bog the whole process down. And even if they where "out" there may not be anything we can do anyway.

Some type of frequency check may work -- something to think about. Thanks.
 

Michael_M

Trusted Information Resource
#7
That's similar to the issue we face. Usually there are a few dimensions which aren't all that important and are difficult to check -- you may have to cut parts, etc. If we do that for every setup (especially for a few hundred parts), it can bog the whole process down. And even if they where "out" there may not be anything we can do anyway.

Some type of frequency check may work -- something to think about. Thanks.
For (some) internal Dimensions we use flexbar repo rubber but this takes a bit to setup and does not work well for constant dimensional checks but it is better than cutting a part. If possible, we try to set up the machine so we can use one dimension to verify another dimension: one tool runs two diameters so if one diameter is good, the other (theoretically) should be good as well.
 

Attachments

Thread starter Similar threads Forum Replies Date
M IATF 16949 8.5.1.3 Verification of job set-ups - Do we need secondary check? IATF 16949 - Automotive Quality Systems Standard 7
G MSA check list to audit IATF 16949 - Automotive Quality Systems Standard 8
M How Supplier Capacity check is done by competitors Manufacturing and Related Processes 0
J Standard used to determine if check fixture gauge is acceptable Reliability Analysis - Predictions, Testing and Standards 2
M MDR requires the NB to perform "tests in order to check that the quality management system" EU Medical Device Regulations 3
G Is it common to do a repeatability check during calibration of an instrument? General Measurement Device and Calibration Topics 5
V CAPA effectiveness check Nonconformance and Corrective Action 3
A Statistical Analysis - Check if these organisms at different concentrations affect the growth of wheat seedlings Using Minitab Software 4
G Oversized Threads - What sized stab pin would be best to quickly check for oversized thread holes General Measurement Device and Calibration Topics 5
G Stab Pin Size For Check Gage Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
B AS9110 Audit Check Sheet wanted Excel or Word Document AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 2
J AQL for Effectiveness Check - What AQL tiers to use on this type of sampling? Nonconformance and Corrective Action 9
G From an ISO 17025 auditor perspective must micrometer calibration check anvil flatness? General Measurement Device and Calibration Topics 4
F Position tolerance check gage manufacturing Inspection, Prints (Drawings), Testing, Sampling and Related Topics 8
S The procedure for replicate check in calibration lab as per ISO 17025 General Measurement Device and Calibration Topics 2
F Design check list for Cable and Wiring Harnesses Manufacturing and Related Processes 6
R Mass production handover check sheet (IATF 16949) IATF 16949 - Automotive Quality Systems Standard 1
bobdoering Handy training tip for SPC - the Check Engine Light Analogy Statistical Analysis Tools, Techniques and SPC 0
R Please help me with attached copy of AS 9100D internal audit check sheet AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 2
B FDA Philippines has no check or balance outside the health department Supplier Quality Assurance and other Supplier Issues 3
Crusader Product Completion, Birth Cert, Product Check sheet - packaged with product Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
C Serialization at Final Quality Check ISO 13485:2016 - Medical Device Quality Management Systems 3
T Example System & Process Audit Check Sheet for IATF 16949 IATF 16949 - Automotive Quality Systems Standard 1
L Signal-to-Noise (S/N) Ratio formula check Design and Development of Products and Processes 2
M AS9100 7.6 - Check Method - PO Information AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
S GR&R for a Stopwatch used to check a built-in Machine Timer Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 6
R ISO 13485:2016 Clause 6.2 - Effectiveness Check ISO 13485:2016 - Medical Device Quality Management Systems 1
P Looking for a company local in Wyandotte, Mi, to come in check noise levels Manufacturing and Related Processes 2
M Difference between a "check" and a "test" Manufacturing and Related Processes 7
M Proper Gauging - GD&T - Attribute gage to check true positioning on the shop floor Inspection, Prints (Drawings), Testing, Sampling and Related Topics 6
S How to check runout on Id to ID diameters Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
Y Is it possible to check the authenticity of a CFDA registration certificate? China Medical Device Regulations 7
M More than canned audit check-sheets? Auditing the Engineering Department Process Audits and Layered Process Audits 5
P Searching for a complete audit check list based on ISO14001:2004 ISO 14001:2015 Specific Discussions 1
V Internal Audit using Plan, Do, Check, Act - Way to go? Internal Auditing 11
S Elisa kits for poultry disease check up companies US Food and Drug Administration (FDA) 3
F Check List and Questions for Auditing Monitoring and Measuring Devices General Measurement Device and Calibration Topics 1
E How to perform Discrimination check for Dial Indicator? General Measurement Device and Calibration Topics 2
B How to check the parallelism error of v axis w.r.t to lateral surfaces General Measurement Device and Calibration Topics 1
L Most appropriate Auditor to check the FMEA & PCP of a Manufacturing Process IATF 16949 - Automotive Quality Systems Standard 5
K Too Simple an Internal Audit Check Sheet? Internal Auditing 10
D Samples & Inspection Check Sheet Templates Inspection, Prints (Drawings), Testing, Sampling and Related Topics 2
Q Chrysler required FMEA and Control Plan Document Audit Forms and Process Audit Check FMEA and Control Plans 7
B Capability Study => Check %Study Variance and NDC? Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 7
C Ways to check to see if the gage is being used General Measurement Device and Calibration Topics 11
H USFDA -QSR Audit Check List 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 5
S Destructive Attribute MSA for Simple Water Leak Check in Trailers Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
L Quick way to check spline pitch runout for machine operators Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
C MSA-4 Attribute Kappa Template - Verification Check Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
C GR&R MSA-4 ANOVA Excel Template Verification Check wanted Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5

Similar threads

Top Bottom