Production Inspection

The module iQ-FEP (Fertigungsprüfung) covers all kinds of production exclusive mounting inspection

• Single part inspection
• charge inspection
• laboratory examination
• 100% inspection for small lots
• sample based inspections
• 100 % control via a link to checking automates

iQ-FEP uses other relevant iQ-Basis-Moduls.

Inspection Planning

The general functions are described in the flyer of the modul iQ-PLAN. Special enhancements of the inspection planning are listed below.

• planning of variants, considerable reduction of planning activities
• generating inspection plans based on CAD-draws via an interface program
• relationship between characters (calculated values)
• comprehensive SPC precondtions, it has to be regarded that qs-STAT (Company Q-DAS) is completely integrated in iQ-FEP
• maps of drawings, pictures etc. on plan or character level

Generating Inspection Orders

Inspection orders can be triggered by a PPS system or manually.
Following forms of organisation apply

• every production order one shop order
• one shop order for many production orders; in this case the inspection order for the material id is set up once for a long period. Every production order is assigned to a part of a use decision that contains a number of samples of the production order.

• different assignments
• shop order corresponds to inspection order
• shop order with operation corresponds to inspection order with equivalent inspection operation
• transfer of information about production from shop order to inspection order
• material id
• producing department
• product quantity
• further plant specific information used
• inspection plan for inspection order generation; assigned material or alternatively enter data during manual generation

Inspection Order

All functions described in the modul iQ-PAUF are still available, further functions concerning production inspection have been added, the following are important

• unlimited samples
• sample size can be increased or decreased
• sample size = 1 allowed (labor examination, single inspection for a batch)
• unplanned characters for unexpected problems, discovered while inspecting or during global inspection
• inspection according to several drawings of the plan or at character level
• analogous inspecting by pictures
• data gathering for qualitative and quantitative characters on paper (forms)
• connecting standard and complex gauges via a link to multiplexers
• gathering shop order information
  • charge number
  • machine, tool cavity
  • producing department
  • produced amount of a sample inspection at present
• information about sample
  • time
  • inspector
  • events; reasoning with individual text or catalogue, supported reasoning about infrequent processes etc.
• information about inspected part
  • serial number
  • event concerning inspected part
  • changed initial values
• information about inspection operation
  • used gauge types and gauge ids

Use decision

Analogous to the receiving inspections production inspections can be documented not only by the inspection order but also by a comprehensive use decesion. All decisions are combined with the quality history of a material for each character.

Distinctions between receiving and production decisions

• you are not forced to make a decision e.g. only negative results have to be documented
• you can make a decision at any time
• you are asked to make a decision if a result is negative

The decision covers

• the duration of the entire inspection order
• a part of an inspection order (from sample to sample or for an entire period)
• one sample
• a specific lot of parts, identified by serial numbers
• Additional information about use decisions
  • production period from / till
  • charge no. from / to
  • serial no. from / to
  • information about charges
  • machine, tool, cavity
  • no. of defect parts
  • defect modes and causes
  • amount of defect parts
  • reason for disposition

The use decisions are displayed in extensive surveys.
The intensity with which this technique is to be applied is preconditioned in the master data of part’s.

Evaluations

There are several evaluations concerning the production inspection. Therefore a complete description is impossible.
The most important features of qs-STAT are listed below:

• several types of control charts
• Wertestrahl
• distrubition diagrams, probability graphics, normal, log normal, Weibul etc.
• confidence intervals
• CHI²-networks
• Pearson function, Johnson etc.
• several statistical values
  • mediun, average
  • variant, range, out of limits rates
  • cp, cp_k, PP, Pp_k with confidence interval
  • test methods like Sweet-Eisenhart, CHI², Shapiro-Wilk
• controlling of distribution models by Shewart charts, F-test, T-test
• further evaluation techniques