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Next Day SPC

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This topic contains 10 replies, has 7 voices, and was last updated by  Craig 12 years, 4 months ago.

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  • #47160

    Because
    Participant

    I have a new job in a manufacturing plant that does “next day” SPC. Each night the manufacturing data is extracted from the WIP tracking software, and manipulated with visual basic macros to make about 40 excel spreadsheets. The next morning each process area supervisor and engineer are expected to view the SPC charts.  The operators almost never see these charts and are trained to send the product on as long as it is within specification. The WIP tracking software is not capable of allowing frequent data extraction (the techs say it will slow the system down). The current SPC “owner” says that real time SPC is not possible at this factory.  Have any of you ever faced similar situations? I don’t see the next day SPC being real effective here for problem solving.  I’m looking for ideas to “shift the paradigm”.

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    #156912

    Mikel
    Member

    Ask the current SPC owner if they have ever heard of a pencil and a piece of paper.

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    #156914

    Adam L Bowden
    Participant

    Stan – I agree – your point leads to operators accountability and time lags.   Systems that centralize the data and have a time lag does not empower the operators to see what’s going on in real time.  A pencil and piece of paper, or other real time feedback system, will change the ownership and accountability of quality.

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    #156923

    Restagno
    Member

    In your company, is the work of going thru the SPC analysis worth doing?
    The reason of this question is that if the quality of your product is good enough that keeps your customer happy,  and the stockholders of your company are not really affected by the customers complaints, then there is not really a strongh enough motive to improve and most importantly, to convince production to use SPC concepts!
    What do you think?

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    #156928

    Adam L Bowden
    Participant

    Customers can still be happy if they receive good product within specifications – but what of:
    – the scrap that is produced in production yet hidden in the eyes of the customer,
    – what of the variable performance of the product due to significant variation within tollerance – Just take the the quality levels of some foreign cars (not trabant) who’s engines last for 1/4 million miles and who’s engine makers strive for high levels and use control charts to understand and control production variables.
    – What of the culture –  the employee accountability or empowerment or do you have a Managed, beaten and demoralized production workforce.  Dio you have a centralized quality department or are employees accountable for their own work ?
    My 2c worth.
    Adam

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    #156931

    Restagno
    Member

    Adam,
    You are right. These are very strong reasons to improve processes and use tools such as SPC among others.
    My point is that if management is not real motivated to drive improvement -or at least make a management function accountable not only for quantity but quality as well- then our friend will have a tough time convincing people about improvement, let alone using and analyzing yesterdays data… to start, do you have kpi’s? (Key Process Indicators) that could help you greatly!!

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    #156932

    CT
    Participant

    What do I think?
    Anything worth doing is worth doing right.
    1) Go fix the system so that it runs normal when data is ran.
    2) Fire the IT guy that tells you it can’t be fixed
    3) Train your people on the ends and outs of SPC and why its important to the process. Show them exactly how much money is lost when they produce scrap, and or rework. Give Specific Examples as to the cost savings that can be generated. Expose the mythes about lost time and lost production due to having to chart a process.
    4) Put a “Do it right the first time” sticker on every operator panel in the plant!
    5) Since you already have the data, Start an OEE program to prove your SPC improvment
    CT

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    #156939

    Because
    Participant

    Our product has a 60% yield, not including the components that go into it.

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    #156940

    Because
    Participant

    The engineers do seem beaten down. Management has gone through a couple of turnovers recently, and the current crew is prone to micromanagement.  My approach is the squeaky wheel, where I keep bringing up real time SPC at appropriate moments.

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    #157416

    Dr
    Participant

    Nest day SPC is too late. You are in need of a real time on line system to which operators can respond immediately to out of control and out of spec production. A pencil and paper system will work fine but you might consider computer generated charts….Your management seems way behind the times. This will be a tough sell! Good luck.

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    #157423

    Craig
    Participant

    I agree with Stan’s original post, but he forgot to include a calculator along with the pencil and paper! :-)
    Why not review your next day SPC charts and single out a manageable number to do manually? There must be some critical characteristics that would benefit from some real-time control. I am thinking back quite a few years ago when one of my organizations transitioned from paper to computer generated charts. If I am not mistaken, we used StatGraphics. The measurement system could communicate with the PC and statgraphics plotted the data. Something like that would help also on a limited basis.
    I am sure that there is value add in the next day SPC charts. You have already invested in the IT resources. Keep plotting them and use them to plan your next generation control scheme. Start thinking of potential OCAPs now so that you hit the ground running with real time SPC. The worst thing you can do is force an operator to manually plot the data and yet have no reaction plan for OOC conditions.

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