Part 2: Multiple Fixture Machining & Manufacturing
In this series: Part I, Part II, Part III, Part IV, Part V
 In Part 1 of this series Joe Stein, Quality Manager of Tall Oaks Metals, told how Strategic Quality Audits helped him find the root cause of his casting problems. He was amazed that it was so much cheaper to work on their quality problems with the help of an inspection service that truly matched his company's needs. "The Strategic Sample Audits they performed on my cast parts gave me the data to find the root causes of the issues, as well as setting up the process to revisit for future problems," Joe said. "All for a fraction of the cost of a full blown sort."
Joe was ready to tackle the next problem giving him headaches. His new inspection service asked Joe what other
processes might have caused his previous controlled shipping and containment issues. In recent months, his machining
cells had generated more than a few customers complaints, and machined parts put him in three Level 2 containments
in the past year. "The problems are intermittent," Joe explained. "We can't 100% inspect our problem parts, it's
just not cost effective." The solution was to design a strategic audit that would help find the root causes for his
machining cells.
Targeting one of Joe's most problematic machining cells first, they formulated a plan to capture parts for a
Strategic Sample Audit. The process started with numbering the twelve fixtures used to hold the raw parts on this
machining cell. They would collect 48 parts from each shift, with each part numbered to correspond to its fixture
and run sequence. One full round of parts would be collected from shift start, and one immediately after each
break.
The inspection of the audit parts was extensive. They were each checked on the set-up operator's gauging station
fixtures for all customer-required specifications. When the data was put into I-chart format by fixture and sequence,
a pattern of potential failure began to appear.
The data identified two of the twelve fixtures that were producing parts out of the limit of the specification on
every cycle. The parts were not rejects, but the process was out of control on these two fixtures. The two fixtures
were checked by maintenance, who found that each needed several springs replaced on the parts holders. Once replaced,
the fixtures produced parts that were back in control. A repeat audit confirmed that the problem was solved.
A Case for Sampled Audits
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to see the rest of this series on the use of Strategic Audits. |
A sample audit is all about the data. We know from statistics that a sample is representative of the whole, so
we can use a strategic sample to look inside your production and report data that can be assumed to represent the
entire run. Good data presented on an I-chart can give you the direction you need to tackle the largest issues first.
Couple that with strategically sampled data that pinpoints when and where in the process the problems occur, and
identifying a root cause becomes much easier.
Sample audits can be used to reduce the need and dependence on sorting activities. They can be done ahead of
containment activities to speed the analysis and get you out of containment sooner. In addition, they can be used
for changeovers and start-ups as a preventative deterrent to eliminate problems as soon as they start.
 Being a Quality Manager for an automotive parts and components manufacturer is a tough job. The stress levels can be overwhelming with pressure coming from both your customer and your own co-workers in production. When things start to go wrong, they can quickly spiral out of control if you cannot identify the root causes of the issues and get them resolved quickly. The data needed to identify the root cause can be elusive when the problem seems to bob and weave like a prizefighter. Utilizing Strategic Sample Audits helps Quality Managers locate and knock out the problems.
Continental Quality Engineering has experts in all aspects of Strategic Sample Audits. Scroll down to email o contact us today, or call (800) 875-4557.
In this series: Part I, Part II, Part III, Part IV, Part V
Wacky Patent of the Week
The inventor of this week's wacky patent invented an elongated football, designed to be easier to catch and safer.
According to the patent, "...the standard football is often difficult for a person to grasp and, particularly in the
case of those possessing relatively little skill in the techniques of the game, injuries can be sustained merely by
mishandling the ball or being struck with it."
Good thing we have people like this inventor looking out for us!
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