Incoming Inspection Reduces Production Delays

It’s really interesting to me (well, maybe I’m weird!) how improvements in procedures in one area of a company can have such a profound impact on another area, or on the entire organization.

Take company A, who implemented an effective incoming inspection procedure as part of their ISO9001:2000 quality system. Prior to implementing the quality standard, they did pretty much what a lot of companies do…..they have a guy doing receiving who’s been there a long time and “knows” everything about the job. They’ve been dealing with the same vendors for years, and they just accept the fact that a certain number of defective products will be received.

Of course, these defective products were often not discovered until something didn’t fit in production. The problems are usually too small to detect without using a micrometer or calipers. But when their vendor’s defective product was discovered, now the whole production line has to be stopped, and there are no good parts with which to make finished product.

After implementing ISO, an effective incoming inspection program was implemented, with a sample of 5 units inspected out of each 100 received. It takes one person an extra 4 to 5 minutes to receive each batch of parts from the vendor, once per day. But overall the company has saved about 2 hours per week, for their production crew of 4, for a total time savings of 8 man hours per week saved. Not to mention shipments are made quicker, and customers are happier.

There was a bit of resistance by the receiving guy at first, no one likes to be told to change his ways, but the company ended up saving time, money, and increasing their sales.

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6 Responses to “Incoming Inspection Reduces Production Delays”

  1. Ed Bones says:

    A point not considered is the fact that the inspection made nothing better, the supplies remained unchanged, but the cost of procuring the parts increased.
    The real solution to the organisation’s problem would have been to require the supplier to carry out the inspection to the same level, using a valid sampling plan and appropriate management activity to rectify failings. That would have led to an improvement because of the additional supplier overhead.

  2. Hello! How are you?
    I’m 100% agree to have a receiving inspection. I’m looking for some kind of short training program 2-3 days for a inexperience person to be train then having a certificate for Electronics/mechanical inspection.
    Do you have any ref. or suggestions.
    Thank you very much.

  3. Timothy says:

    That sounds like a pretty specialized training program you need. I am not aware of any reference material particular to your industry. Does anyone have any suggestions?

  4. Why not try a Trackstick for this?

  5. Matt Morris says:

    Finding customer specific requirements has long been a challenge. In fact, a survey of current automotive suppliers found that a significant number did not know where to go for the latest applicable customer specific requirements. For registrars and end users, this represents a serious problem. How can rules be followed and enforced if they are not readily available?

    It is with these challenges in mind was created. Here you will find a community to access, share, and discuss customer specific requirements.

    Please understand that the content of this site will take some time to develop as we work hand in hand with each of you to build a comprehensive database of the thousands of available customer specific requirements. We ask that you join us in our cause as we attempt to build something great for the common benefit of the quality community.

  6. Cindy says:

    Hello, I have been reading your comments and are very interesting. Someone of you know if there is any kind of association or group for people that are dedicated to suppliers and receiving inspection area. I am working in a medical device company and I want to be updated about this area.

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