Pat,
Without going into a lot of detail. We use operators as our inspectors. The
key to the success of this style is making the operator aware that signing
off an operation means that it was performed and meets the quality
requirements necessary. There are consequences when an operator passes bad
hardware. If an operator has issues with what they are inspecting they can
record the information and get a ruling on the acceptability of the issue.
Our operators are re-certified every year and must pass an eye exam. Our
Quality department simply serves as an audit function, they can pull up a
chair next to an operator at a moments notice and verify everything from the
build documentation to checking the shelf life of materials used that the
operator is using. These audits take place once a month for each operator.
This system has proven effective because our operators take it very
seriously when stamping off an operation. Coming from an operation many
years ago where we had the usual Inspection by Inspectors, this was a
culture shock for me. I can say that it has totally eliminated non-value
added "cosmetic" touch ups that used to occur when workmanship elements were
in the gray area. It seems to work quite well. Another element of success is
that our operators are paid well and turnover is non-existent.
My recommendation would be to start this as a pilot program using your core
operators and gain some comfort level, then go from there. Good Luck!
Bill Kasprzak
Moog Inc. Manufacturing Engineering, Electronics
> -----Original Message-----
> From: Diamond, Pat [SMTP:[log in to unmask]]
> Sent: Tuesday, November 05, 2002 3:57 AM
> Subject: Inspection levels
>
> Dear all,
>
> I would be interested in your thoughts/comments on 100% operator
> self-inspection with no overcheck, my company is thinking of introducing
> this and it frightens the life out of me. At present we run with
> overcheck
> covering operator self inspection and and our faults to joints soldered is
> running at about 9%. We do not manufacture PCB's, this is purely on
> solder
> cup and Solder eyelets with all of it's inherent wire stripping etc.
>
> Does anyone out there have any experience of this?
>
> Regards,
>
> Pat.
>
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> Pat Diamond
> Senior manufacturing Engineer
> Weston Aerospace Tel: +44 (0)1252 868194
> 124 Victoria Road Fax: +44 (0)1252 370298
> Farnborough, Hampshire, GU14 7PW Web www.westonaero.com>
> England Email mailto:[log in to unmask]
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