If you want to answer this question, you should know two concepts in this question. The first one is what means NG parts . Another one is how to describe the escaped.
NG parts means to say no good parts which cannot meet the criteria of the quality or industry. NG parts are not only the cosmetic NG also including other NG such as function NG ,Reliability test NG ,ORT NG ,GP NG,ROHS NG etc.
Escaped means the NG parts follow to your customer company or end user.
When we discussed about this question, we should concern below two factors to investigate the reasons then we can make it clear to avoid this problem happened again to destroy our relationship with customers.
One major factor is technical problems.
We can separately discuss about the technical problem. Normally we can list below items.
• Criteria—no defined the criteria or defined not clearly or defined not completely. If the criteria isn’t sufficient for well known by all employees in company, the NG parts might be escaped to customers.
•Lake of knowledge of KAPPA ,GRR,ARR
•Light intensity is the most important inspection factor especially for cosmetic inspection. Normally we set the light intensity in 900-1200LUX for Apple or Microsoft project.
•The inspection time is not enough. During the mass production, in order to get more capacity and higher productivity ,the production line speed will be adjusted to more higher and higher cause the inspection time will be shortened. Operator don’t have enough time to inspect the parts.
•The bug for process flow. Clearly, final inspection should be in the end of line then for packaging to ship to customers. But some times there are still a few of stations after FQC ,for instance, whipping dirty or remove the residue of glue. Even though these parts have been passed by FQC but also will be damaged in following stations after FQC. Meanwhile, we need to check if the package material can protect the finished parts well during the transportation.
•Inspection distance. If we didn’t define it well follow customers directions , we cannot detect all defects of parts immediately. Normally we defined that the inspection distance is more than 35cm.
•Inspection angle. Some defects only can be detected by special angle. So we allowed operators to rotate the part by 360 degrees.
•Inspection tools. Sometimes, some of defects need to use inspection tools to help to enhance the accurate of judgment.
•Eyesight of inspector. This factor is normally be missed when we hire the operator to be inspectors. It’s the key factor for escaping.
Another major factor is operation management.
•Lack of training for criteria. Once we defined clearly the criteria of product, so we need to train the whole peoples of production line.
•Production area is mess. For examples, no define the area for parts to be inspect , parts inspected or NG parts. Let anyone come to production line can recognize what’s these parts and where are they from and where to go.
•Lake sense of quality mindset. Sense of Quality mindset is almost the essential training for new staff training when they joined the new company. But , absolutely , it’s not enough. Our production supervisors and line leader should training it in job by daily meeting.
•Not clear for SOP. Operation ME in charge of making SOP. But the SOP is not ME just for operator. So it need to consider the real operation method and tools and how to make their job more efficiently in production line.
So, today I organized two major factors and so many items in the report. If we know the reason so we maybe have known the next step to solve these problems then avoid the escaping issue happened again in the future.
Thanks for your time.
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