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Mistake proofing for Weld missing problem.

Six Sigma – iSixSigma Forums Old Forums General Mistake proofing for Weld missing problem.

This topic contains 4 replies, has 4 voices, and was last updated by  AT 15 years, 1 month ago.

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  • #34882

    AT
    Participant

    Hi friends
    Our’s is a fabrication industry & operator intensive.So,obviously we have weld missing & other non-conformities due to human errors.Can you help me with some of the POKA-YOKE’s(Mistake proofings)for these type of errors.Your help is greatly appreciated.
     

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    #96814

    Gabriel
    Participant

    It is very diffecult to answer that question without a better idea of the process.
    I can imagine (don’t know if it would apply to your process) a device where the parts to be welded are set, then the parts are welded together, then the device rotates horizontally and the welded part is unloaded in a box on the opposite side of the table, out of the reach of the operator, so only parts that went throug the device can be put in that box.

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    #96834

    LukeHCS
    Participant

    Hi Ramesh,
    I work in a high mix, low volume environment, operator dependent w/zero defect requirements, and not knowing your specific process and giving a shotgun answer. Here is our methodology.Determine who the crossfunctional team is, training on mistake proofing(many books and articles exist for information). Gather all defect data, customer complaints,etc. and observe the process together.Our team approach is first, process map, then indicate what the defects are, where found and current inspection requirements.Next brainstorm w/facilitaor and crossfunctional team all mistakeproofs for EACH area of the process map identified as a source or root cause and list them.The ranking we use is 4 quadrant based on low cost/time to implement(TTI) and low impact, low cost/TTI and high impact, high cost/TTI and high impact, high cost/TTI and low impact.After ranking the first level mistake proofs are implemented (after prototyping by worst case challenge operater, otherwise, not mistakeproof) First level being low cost/TTI and high impact, then we moniter the defects to understand if next level is required. This can be done without the team as well but you miss out on the power of brainstorming and all can all be implemented quickly.
    The key is not to go to the next level until you have implemented and evaluated.

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    #96883

    Chen
    Participant

    Hi Ramesh,
    We are dealing with the same problems.
    Please give me more info about the products, processes and the kind of mistakes and I can probably help you.
    With best regards,
    Bernard (bscholte@koni.nl)
     

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    #96896

    AT
    Participant

    The process is co2 welding of beams & making it as a structure.Each product has got more than 50 welding places.Some places are not visible from outside.All manual operation.It is not like a pressed component where next operation can easily detect the misssing hole or slot.It is easy in mass production.but ours is a capital goods Industry.Hope you got enough information.
     

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