THE ADDED VALUE OF AN INTERGRATED INSPECTION PROCESS USING SPC

This paper aims at challenge the perception of inspection as being a non-value adding activity by demonstrating the potential value and additional benefits that a lean and effective inspection process can have on the overall... [ view full abstract ]

This paper aims at challenge the perception of inspection as being a non-value adding activity by demonstrating the potential value and additional benefits that a lean and effective inspection process can have on the overall production performance, and how it can help drive continuous improvement and bring real tangible value to the business and its customers.

As a SC21 Silver award winning supplier to the Aerospace industry, J.W.Kane must maintain a right first time (RFT) of no less than 99.5%. The challenge for the company is to continue meeting this high standard whilst increasing throughput and maintaining resources levels. Through a 2 year KTP project, in conjunction with the NITC, the implementation of SPC and a customised company intranet enabled the development of a lean inspection process, assisting the transitions from end of line inspection to in-line using “best in practice” techniques and countering the opinion of inspection as a non-value adding activity by demonstrating the true value of an effective and efficient inspection process.
The project focused on the development of a customised company intranet to provide an integrated production process that allowed quality inspectors instant access to the information and databases that they require during the end of line inspection process with one scan of the job card. The intranet also made available additional information as part of the integration and inclusion of SPC, information such as: machine operator feedback, non-conformance records, SPC control charts, and a parts inspection history. The inclusion of a comprehensive parts non-conformance history reduced the companies reliance on individual knowledge, embedding the information within the company. As the network also enables machine operators to retrieve and input component information during production, providing real-time analysis and inspection feedback, greatly aided operators in their continuous improve project.
The network has enabled a lean inspection process by reducing the key wastes identified during the process analysis, which were: time spent locating documents, inputting data, getting information from operator. Data and part specific information could be input directly by operators and accessed from anywhere with access to the network. The data input by operators was used in the creation of control charts that enabled inspector to verify batches with smaller sampling regime and at the same time greater degree of confidence that the parts conform due to the stability of a Six Sigma process, leading to a reduced work load and average inspection time per batch without compromising quality and helping the company target higher value work form the likes of Airbus or Boeing. Additionally, this will help the company achieve SC21 gold award and move to becoming and exemplar tier one supplier to the aerospace industry.