Packaging Quality

[BML]

I'm in a build-to-order manufacturing environment where we paint several types of parts and then package them. Our process involves pulling the parts off the paint line, storing them in baskets, then pulling each basket to a work station. At the work station, an operator identifies the part, looks up customer orders, and packages them accordingly. Our biggest problem is wrong or missing parts; damage, fit, and finish issues trail far behind. Does anyone have any suggestions for *simple* methods we could implement to improve this aspect of quality?

 

[DeForest]

Color code bins, provide a picture of each part, spatially seperate similar parts to different bins. Track errors to operators and provide additioanl training, include an incentive plan that would include simple awards or recognition to individuals or the group (especially the group - peer pressure or recognition)) for reduced errors.<br>
Is there a language barrier? Is the workload reasonable? Training training training!!!<br>
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Good Luck!!

 

[BML]

Thanks for your reply. Unfortunately we already have that. We've pretty much figured out that we need to inspect a sample of job sites to see if the *customer* is losing the parts. We've tried everything you mentioned and more, and none of it made an impact on the reported numbers. So now we're going to attempt to train the customers ;-)

 

[magna123]

We have similar problems at our facility and we had to implement the training matrix and make the operator more accountable for there actions. We also had our customers sign off boundary samples that allowed us to build to a less stringent quality standard. Our parts are of high visibility on the vehicle in which we apply it. We hold workshops when we get parts back from the customer and make all the employees go through another trainign sesion. I find that sample boards make for a good visual aid aswell &quot;out of site out of mind&quot;, when we incorporate this practice it makes them more aware if the problems and focus on the areas needed. It is very dificult to have them focused when we give them such little resources.<br>Well this made a big difference in our facilty and made our customer very very happy, not to mention our ppm's were drasticaly reduced.<br>I hope this helps it did for us.

 

[kcmazzel]

any chance in addition to training and the usual methods to detect operator error, etc., that the weights of individual parts on the order could be compared against the weight of the end product?