11.2 Case Example Input Material (Sheet metal) - Thyssen Stahl AG

Transcription

1 11.2 Case Example Input Material (Sheet metal) - Thyssen Stahl AG Explanation Product audits are carried out in the form of an internal company re-inspection (Fig ). The scope of inspection amounts to 20 coils (rolls) monthly per working area. The product range consists of the following: - cold rolled sheet metal (KB) - hot galvanized sheet metal (Z) - galvannealed (ZF) - electrolytic galvanized sheet metal (ZE) - hot aluminized sheet metal (AS) - coil coated sheet metal (OC) - other (SO). The selection of the test pieces is carried out in accordance with the instructions of the responsible quality department. Generally, coils packed and ready for dispatch are examined. The characteristics to be inspected are laid down in a questionnaire. The inspection is carried out on the basis of the given characteristic specifications. The characteristics are assigned with position numbers (Pos.-No.) e.g. 011-Labelling, 301 not sufficiently oiled (Fig ). The evaluation scheme is made up of a 5-stage grid, against which each nonconformity is evaluated. For each nonconformity given 5 or more nonconformity points, the cause and corresponding corrective action are to be named. (Fig ) Reporting takes place monthly by the auditor. The monthly results are presented for each working area and supplemented with action plans. The audit result is represented in Fig and

2 Product Audit Process Input Material (Thin Sheet Metal) Planning international company re-inspection Spezification Checklist (Inspection characteristics Work instructions - characteristics - inspection, measuring and test equipment - frequency Selection of test pieces Requirement Quality department Process Work instructions Evaluation >5 Nonconformity points? No Reporting Yes Immediate actions Corrective actions Bild : Product Audit Reinsepection Work Process 36

3 PRODUCT AUDIT REINSPECTION Individual evaluation KW I / KW II Page No.: of _ Insp. Date Product: Order / Pos.: Customer: Ident. No.: DIN-Quality: Order Width: Order Thickness: Packet No.: SPECIFICED VALUES Tol. Width +/- Surface type Pack. weight min Edge trim Tol. Thickness +/- Evenness Pack. weight max Welding SG Protection Type of packaging Cust. Standard Stamping Inner- No. of labels i: o: Surface finish Stable side Outer- min. Type of labels Application Outer- max. Other + Source details Evaluation Explanation Assessment step n 55 n 15 n 5 n 3 n 0 min. 1 nonconf. with 55 points min. 1 nonconf. with 15 points min. 1 nonconf. with 5 points min. 1 nonconf. with 3 points no nonconfs. equals 0 points Rejection of the insp.unit, further processing at cust. premises not poss. Partial rejection, Repair/rework prior to delivery necessary Throughput at cust. premises only poss. with add.costs (e.g extra oiling) Throughput at cust. premises without difficulty, cosmetic faults Reinspection complies with the release results/ cust. requirements. Pos Inspected Method Nonconf. points n Comments characteristic Labeling visual 051 Packaging visual 101 Coil status visual 102 Coil edges visual 103 Outer winding visual 104 Inner winding visual 152 Coil Inner tape measure 153 Coil Weight scales 201 Edge trimming visual 251 Ident. / stamping visual 301 Surface protection visual 351 Coil width automatic 352 Coil thickness automatic 401 Surface finish/coat. visual 402 Surface type/class visual 404 Evenness visual 451 Weld seam visual 501 Stable side visual Corrective actions for nonconformity points n 5: Reinspection carried out Repair carried out Name/Signature Name/Signature Datum Date Fig : Product Audit Reinspection: Individual Evaluation(Form) 37

4 Product audit - Reinspection KW2 Monthly assessment - Individual representation Month: September 1996 Scope of insp. per product Specified Actual Inspection scope per product Required Actual - Cold rolled sheet metal (KB) Hot alu. sheet metal (AS) Hot galvanized sheet metal (Z) Coil coated sheet metal (OC) Galvannealed (ZF) Other El. Galvanized sheet metal (ZE) 5 5 Seq. Dimensions Iden No. Pack No. Cust. No. Width Thick. S G 011 -Labelling H AUTO ,70 6 ZF : color uneven 2 2R E AUTO ,75 6 ZE G AUTO ,90 8 Z R E AUTO ,80 6 ZE : poorly oiled F AUTO ,77 6 Z F AUTO ,90 6 Z : strong buring on edge trim H AUTO ,75 6 ZF R E AUTO ,75 6 ZE : Start of coil 150 m, binding band pressure marks 9 2R E AUTO ,75 6 ZE E C AUTO ,84 6 KB E C AUTO ,84 6 KB : Coil edges slightly damaged G AUTO ,20 7 Z X C AUTO ,80 8 KB : Label dirty F AUTO ,90 6 Z : Occaisional scale H AUTO ,75 6 ZF E C AUTO ,80 6 KB : Medium waviness F AUTO ,77 6 Z : Stripey surface after grinding H AUTO ,71 6 ZF : Inner 10 windings, 10 mm run off center G AUTO ,60 8 Z S S AUTO ,80 6 ZE Packaging 101 -Coil status 102 -Coil edges 103 -Auter wind Inner wind Coil-Inner-Ø 153 -Coil-Weight 201 -Edge trimming 251 -Ident./Stamping 301 -Surface 351 -Coil width 352 -Coil thickn Surfacefin./coat. Prod. Comments* 402 -Surf Evenness 451 -Weld seam 501 -Stable side *Comment: For every nonconforming evaluated with min. 5 nonconf. points, an action plan with details regarding the cause of the nonconformities and corrective actions must be raised! Date/Signature Auditor / Company Inspectors Management / Head of Quality Dept. Bild : Product audit - Reinspection: Monthly Evaluation

5 Internal Company Reinspection - Monthly Evaluation - September KW2 QF-PD de Fries Seq No. Non Conf pts Ident No. Customer Dimension Product Application SG Aggr. Delivery insp. Type of nonconformity Cause Immediate action Corrective action Responsible R AUTO 1580x0,75 ZE Side part 6 IA 2 103: Start of coil 150m Binding band pressure marks Automatic binding machine Nonconforming length was cut off Fine adjusting of the new automatic binding machine in Inspection Plant 2 Finishing Plant R AUTO 1220x0,80 ZE Roof 6 EBA 2 301: Poorly oiled Fault in the nozzle beam Coil was reoiled during the reinspection Fitting of flow meters Finishing EBA 2 Bild : Internal Company Reinspection - Monthly Evaluation