Hello steve,

If you can run the following, it may get you the results to change the "old mind set"
about un-necessary rework.
Take a batch of your assemblies. Split in two sets. Let one set be reworked by the
present process. Keep other set w/o rework. Do functional test on both. Comapre
results. If the results are same then you have data that shows that rework/touch-up is
not needed.

By the way I have used this technique in my past life. Good luck.

"Stephen R. Gregory" wrote:

> Hi ya'll!
>
> I know this is going to be question with no easy answers. What I want to ask
> is how do you go about evaluating the real effort that is being expended on
> rework or touch-up? Then prove what was necessary, and what wasn't?
>
> To set the stage, the process is mainly "gate-inspection" (I know that's not
> desirable) but that's what it is. Past history has been to meet standards
> that match a picture (Martin Marrietta comes to mind). Not whether or not
> touch-up or rework is adding any reliability or value to the finished
> product, or is just make it look like the pictures. (reading between the
> lines;..that quality mindset is THOROUGHLY ingrained here)
>
> So how do you getting a good un-biased snap-shot of what is actually going on
> out on the floor, and then go about changing things?
>
> I believe that there is no simple way. It's going to take a lot of time and
> effort to take assemblies that are in process, identify them by way of a
> serial number or some other means, have a referee (knowledgeable unbiased
> person) inspect them after each major process to determine what (if any)
> defects are on each assembly, then let them continue on through the process
> with the instructions that any rework or touch-up performed on the assemblies
> must be documented as accurately and completely as possible as to what
> defects were observed, where, and why they were reworked. Then afterwords, an
> assessment done on the whole quality process.
>
> As you may guess, there is some thought going around that we rework more
> things than we need to. I'm just trying to find a way that will be the most
> effective, and that will be as unbiased as possible. Also as you may guess,
> this subject can get pretty emotional with the QA folks...I butt heads every
> single day. I want to find a way that nobody can argue with.
>
> Yes, It does still seem a little silly that I need to secretly strategize a
> plan to bring out the realities of the situation in order to convince certain
> people to change their philosophies. But I have been asked to do it, and I
> got the the task because they think that I have a magic solution to change
> certain mind-sets, but I don't. I'm asking if any of ya'll have had to go
> through a situation such as this, and what you did to resolve the obvious
> issues...
>
> Thanks everybody!
>
> -Steve Gregory-
>
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--
____________________________________
Regards,
Pratap Singh

Tel./Fax: 512-255-6820,
e-mail: [log in to unmask] or [log in to unmask]

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