New Production Process Implementation

[mbrown12]

I work as an IE for a company that manufactures cabs for agricultural vehicles. We have twelve products that are manufactured on seven different lines. Due to changing customer requirements, we are going to implement an electronics test that is to be administered to every cab produced. The test devices are to be handheld and will check functionality of things like lights, radio, wipers, etc. Each line will have one test device and the inspections are to be performed before the cabs leave their respective production line. Due to a high turnover rate, and seasonal demands, about forty percent of our employees are temps. What steps can I take to ensure that the temps (and even the full time employees) will administer the test correctly?

[jclark]

It’s good that you are able to recognize the potential problem in this case as opposed to trying the fix the problem after it occurs. There are several preventative measures that can be applied here. First, use one common device/model even if all the functions are not required for every line. This will reduce the complexity and will allow the handhelds to be transferable between lines if you have several that need to be repaired simultaneously. A well-structured training course should be developed and given to each employee who might need to perform this work. Ideally there will be a training video, a spare handheld, and a cab to practice on. Demonstrate all functions including charging, maintaining, handling and clearing faults, etc. Allow the operator to perform all the functions as well. You may need to make special accommodations for language barriers. Maintain a training log and record each employee as they complete the course. Finally, post Work Instructions with pictures (again account for language barriers) at each station that will be using the handhelds.

[kpeacock]

I would definitely agree with JClark. In the case of temps doing inspection and carrying it out well, standardized work instructions should help. Also the use of standardize work will help to keep track of employees and their quality of work. By making the work consistant no matter who is doing it you can hold the employees to a standard metric to measure their work. This again can be helpful in determining which employees should be kept on or let go.

[abhijit]

I am considering that you will have a electronic testing system which will have a logic that will control the test procedure sequentialy. Can we put a display board which will be connected to test setup and will visualy display wether particular test has passed / fail and at the same time it will make a audible beep sound if failed. By this we can confirm that either the test has been really failed or it has been by passed.

This system may prevent the cab being skipped without full testing. This may add somewhat more assurance to process alongwith proper training.

Regards
Abhijit