Training on how to prevent defects, and what to do when you find a defect

1. CONTAINING AND
AVOIDING DEFECTS
T R A I N I N G W O R K S H O P

2. PURPOSETo fully train all members on how to avoid
defects through common operator practices,
and what do to when you find a defect.
OBJECTIVEEquip all employees with the necessary tools to
identify and contain part defects

3. PART 1AV O I D I N G
D E F E C T S

4. HOW IMPORTANT ARE
ACCURATE WORK
INSTRUCTIONS FOR
DEFECT PREVENTION?

5. Work instructions contain valuable information about each and every job.
They may contain common defects and images to go along with them. They
may also tell you how and where to look for defects on the parts. If you
notice something missing from a work instruction, notify your supervisor so it
can be updated. Ensuring our work instruction are as helpful and accurate as
possible will help us PREVENT errors from occurring.

6. ITEM
IDENTIFICATION
Item identification is a form of
communication.
Good communication results in a positive
work environment and positive results.
Ensuring all items at a work center are
properly labeled and identified helps reduce
the chances of cross contamination.

7. ARE YOUR
MONITOR ALARMS
ON?
As an operator, you should always ask if the alarms on your machine
are turned on, especially after startups. In some cases, you may be
asked to check the alarms hourly to ensure they are always on and set
correctly.

8. USING COMMON SOUNDS TO HELP
AVOID DEFECTS
WHAT SOUNDS DO YOU LISTEN
FOR?
WHAT ARE BAD SOUNDS? WHAT ARE GOOD SOUNDS?

9. PART 2C O N TA I N I N G
D E F E C T S

10. DEFECT ACTION PLAN
Notify Support
• If you encounter a defect, page a processor and an
inspector to the press immediately.
Contain Parts
• Complete a full line clearance
• Remove all suspect parts from the production line
Evaluate and Restart
• Note what immediate actions were taken to prevent
the parts from entering into a box.
• Communicate with Supervisor and relieving
of the defect.
• Restart normal production

11. WHAT IS A FULL LINE
CLEARANCE?
• Empty catch bin into the scrap bin - purging of all
defects
• Empty reject bin (if available) into scrap bin - purging
of all defects
• Place any shots into scrap bin
• Remove suspect inspection bin
• Remove suspect boxes from work center
Never do a full line clearance on your own. The QC
inspector is responsible for dictating which actions need
to be performed to ensure the defects are contained.
Work closely with the QC inspector.

12. TAKING ACTION
After a defect is properly contained, the processor will begin a corrective action to fix the
current defect. The Processor and QC Inspector will work closely to ensure the issue is
resolved, once the issue is resolved, the processor will give you the green light to
continue production.
Take action to note where and what the defect was, and clearly explain it to your
supervisor. Also, communicate the known issues to the oncoming operators so they too
can know what to watch out for.