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Wrong part # stamped

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  • #51809

    Waseem
    Member

    Hi everyone,
    We stamp part #s on clips. We have thousands of part #s in use that is why we can’t use one single stamp block for each part  #. What problem we are facing is, let’s say the part # is 752, operator makes mistake like stamping 572, why, because he is using single digit numbers. How can we error proof our system so that he doesn’t make mistake. Appreciate your responses. Thanks, Ws

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    #180774

    Remi
    Participant

    Hai Waseem,
    Talk with the operators. Find out under which circumstances they make the mistakes (most of the time). Find out their improvement recommendations. Brainstorm for improvement Ideas
    Some things I can think of:

    Preventive: Stamp on a dummy first (cost of dummy vs profits of less faults; dummy could be piece of paper); Check automatically with Vision system what the made stamp # looks like and show this to operator/check with wanted stamp # (expensive?); Make #’s  that are expected to be used ‘today’ in the morning and let operator only use prepared stamps in order presented to him (larger buffer of single digit stamps needed)
    Repairative: Stamp softly first; check and stamp final (loss of cycle time though)
    Hope this helps

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    #180776

    SandMan
    Member

    can you post your 5-why for this…?

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    #180778

    IE
    Participant

    well, modify the machine/die that makes the part, stamp it at the same time (progressive die) or CNC machine.
    easy !
     

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    #180779

    MrMHead
    Participant

    Is it possible to use colors on the instructions and setup?
    So 123 will be Red Yellow Blue on the instructions, and when setup occurs if you see Yellow Red Blue you have a bettter chance of seeing the discrepancy before the run.
    Use a combo of different text and background to get your 10 digits.
    Not knowing your process or equipment, this could be totally off-base.

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    #180787

    Taylor
    Participant

    Do you have a procedure in place? What does the procedure say? Error Proof the procedure, Check sheet, etc supervisor/lead sign off of check sheet.  Follow the procedure and hold accountable for not following the procedure.
    Set up procedures are the most lacking of all manufacturing process’. Everyone has procedure for quality and running and daily checks, but very seldom will you walk in a job shop and find a set up procedure in place.
     

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    #180788

    SandMan
    Member

    This is a good idea if the operator is not colour blind. And the number slip looked to be dyslexia… 752, 725. Could an optical / character recognition system catch this?Operator setup crosscheck and sign off also works but takes time.We need more insight before drawing conclusions that this was an employee error or if the training and system are weak to support the role.Post a 5 why review of this as requested… we can help from there.

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    #180853

    Kulkarni
    Member

    I had a similar problem where in we were supposed to number punch the sl. no on the batteries.If it is a three digits then we would tie 2 digits (as good as permanent) and third digit was variable. With this we had minimised 70% of the error. But think can this be automated with forward moving just like the rubber stamp (ink)used in punching the sl.no which goes purely in forward direction.
    vidya

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    #180856

    Mirko
    Participant

    Can you stamp part #s that contain only one time a number?Are the combinations of your digit #s enough?

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    #180864

    Jonathon Andell
    Participant

    Cannot offer a valid solution unless you truly know the cause of the error, which takes a little time and effort. Even if another organization appears to have the “same” error, its cause may differ – so their solution would not work in your organization.It’s not enough to know “what” the mistake is – you must come to understand “why” the mistake occurs.

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