Process Insp.

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  • Process Insp.

    Our QC Dept does 1st off ,In Process, and last off inspection of parts which require measurements using calipers, height gages etc and are recorded in a book.They also do what we call a floor inspection where they go from machine to machine and check parts on a fixture as well as visual insp.

    What kind processes does you quality dept run and are they simular to ours ? Do you/your guys do In Process Insp , last off etc ??

    Coot

  • #2
    Ours is not so formal that we have a policy but we do have in process inspection where roaming inspectors lay out parts and document it mainly because our "skilled" labor does not know how to check their own work if it goes beyond a micrometer or bore gage. It is a shame when the guy roaming around the floor with the know-how to lay out a complete machined part gets paid so much less than the guy reading the paper pushing buttons, but that is the way we do it.
    <internet bumper sticker goes here>

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    • #3
      We don't normally run production. We build the dies, find out what the part is, make adjustments, check again, make adjustments, ect, until the parts right. Then we do 6 pc full inspection, Gage R and R, and CPK. Then normally we are done unless there is an engineering change.
      sigpic

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      • #4
        in theory and in practice

        We do a 1st article for all new set-ups. But unless there is a problem or it is a first time run for a part, the machine keeps running while the 1st article is processed. I should point out that much of our work is very complex and often takes 100+ hours of machine time for a mill operation. We also review the completed order of parts and spot check all features. At this point we normally 100% check critical features. (any total tol of .002" or less,threads, and anything known to be critical for that particular part.) However sometimes the "hot,hot,hot" mentality inspires managment to tell us "minimal" inspection & "SHIP IT!". In theory we also do some in-process at the machines, but in reality there is rarely time for this. But any time a machinist has a problem or question they come and get someone, so we do spend a significant amount of time at the machines. I should also note that different parts are treated differently based upon the customer requirements and the particular part. The above method applies to all parts, but some of the more complex/difficult/expensive stuff gets the fine tooth comb/white glove treatment.
        sigpic"Hated by Many, Loved by Few" _ A.B. - Stone brewery

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        • #5
          our parts are tagged and identified and move thru the shop on "travelers". at each operation there is an insp stop for first piece inspection and and aql sample for each operation. we have cmm programs in place for most operations and our machine operators run the programs on the shop floor as needed.
          sigpic
          Southern Man don't need him around anyhow!

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          • #6
            We inspect the first piece off the machine for new setups (they have to wait untill complete), we do in-process inspection (usually the first part of the shift and depending on run time one after lunch) and final inspection using using sampling sizes per mil-std-105. We also have what we call "operator inspection forms" that they also have to inspect various features to ensure tools are not wearing (this is usually 100% inspection of critical features and one per shift inspection of a few non-critical features).

            We also have inspection operations after each outsourcing operations (heat treat, plating, etc...)

            We have learned to stick with these methods even while trying to reduce throughput and inspection time because of customer rejection rates are very, very low and have a reputation for having outstanding quality (not trying to brag, just very proud).

            Dan

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            • #7
              We have first article and inprocess paperwork for our operators. They do all the first article and inprocess inspections themselves. QS checks only what the operator cannot do without a cmm like true positions ect. We train all operators on how to do it for themselves,read blue prints, layout on surface plate, and any other hand tool that they use. After they get trained they become certified operators that can sign off on the parts that they made.
              QS is responsible for training, auditing of certified operators, PPAP, gage setups, gage calibration, COC, FEMA, Process capability studies(CMM) and any other duties as assigned by Quality Manager.
              Time for the Trolls to leave.

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              • #8
                I only check first off prototype parts. Once we know they work, the parts are out sourced for manufacturing. It makes for a less boring day, when you never know what your be measuring from day to day.

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                • #9
                  We do 1st Art. on every part for every run. Engineering creates an in process inspection form for checking the "key characteristics". The first piece for the operation is completed by the operator and then brought to the inspector to verify the recorded results. The operator and inspector frequency is filled in using the company AQL and the operation continues. The 1st Art. is completed along the way and verified at completion.

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                  • #10
                    We are in automotive stamping, and do 1st article, in-process (about 5 times per shift) and last article. There is only one QC inspector/CMM programmer/CMM operator per shift, so we have written CMM programs for the majority of our work. Everything else is done on the rock or the optical comparator. We do have a few fixtures for the operators.

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                    • #11
                      Our operators do the 1st piece and last piece as well as in-process checks.
                      I write the songs that make the whole world sing...er...
                      I write the programs for the gages, ppap, quality concerns, cap studies, and anything else 'they' can think of...
                      KB
                      RFS Means Really Fussy Stuff

                      When all you have is a hammer - everything looks like a nail....
                      sigpic

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                      • #12
                        I make up the critical Dim sheets for the inspectors, as well as Dwg's samples etc and program the Vision System among other stuff LOL.We do alot of Automotive stampings as well, the Setup operator brings in 3 pcs for the 1st off approval, then once it is ok it's given a green tag and the operator can run.The 1st off inspector can get anywhere from 12 to 40 1st off's to do per shift.


                        Coot
                        Last edited by thecoot; 04-26-2006, 12:42 PM.

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                        • #13
                          We use numerous processes to make the components that go into the assemblies we make. CNC lathes and mills; Cold head and thread roll our own bolts; roll form sheet metal; hydroform sheet metal; blank, pierce and form stampings;TIG weld, resitance weld; on and on. Makes inspecting fun. You learn a lot of different processes.

                          We have six inspectors, if I include myself. Inspection performs first and last piece on most operations. Sample inspection on some. We also have some operators/set-up people who are allowed to inspect and sign-off product processed in their department. SPC is performed by the operators on most processes. We have a final inspection prior to shipment using various sampling plans. Inspection also inspects incoming material.

                          I'm not as involved in the first/last piece work as I was. I am the Senior Inspector and help when the inspectors aren't sure how to check things. Also, primary CMM programmer. Perform AS9102 FAI to assist the QE. Internal auditing too. AND, when there is a problem, I usually get involved to figure out what went wrong.
                          When in doubt, post code. A second set of eyes might see something you missed.
                          sigpic

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                          • #14
                            I check things on days when the Shop Forman isn't afraid of rejections.....
                            sigpic Life is not a journey to the grave with the intention of arriving safely, but rather a skid in broadside, totally worn, proclaiming WOW What a ride!

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                            • #15
                              It's good to read all these responses, may try to incorporate into our business. I've only worked in manufacturing at this one job (for 20 years) and have not been exposed to all the different methods that you use in your business.

                              Thanks,

                              Dan

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