This document discusses operator self-inspection, where production workers are trained to inspect their own work. It provides several benefits over inspection solely by quality personnel, including immediate detection of errors and greater incentive for operators to accurately identify issues. Implementing operator certification requires training operators and managing the human aspects. Principles for operators include not accepting or producing defective work and addressing any issues. The workflow is described both with and without self-inspection. Mistake proofing, root cause analysis, visual management tools, and discipline are important to maintain quality. An operator self-inspection program and process audit procedure are outlined.

1. OPERATOR SELF
INSPECTION
I produce I check
Not pass defective good
Ulhas Kavathekar
6th June 2022

2. Is it better to have appraisal done by QC
inspectors or by production operators?
 This question is often overlooked by
manufacturers. Yes, inspection is necessary,
even in very good factories. But inspectors are
not!

3. What is Operator Self Inspection
 Operator certification is the process where
production workers are trained, authorized, and
given the necessary resources to inspect their
own work.

4. Purpose: Operator Self Inspection
 To provide immediate detection of operator,
machine, and process errors.
 To provide an alternative to 100% inline
inspection by quality personnel.
 To provide greater incentive to manufacturing
personnel to identify part status accurately.
 To provide positive feedback to operators to
prevent re-occurring errors.

5. Challenge
 Operator certification, by its name and nature,
is a human-based change
 Managing the human interaction with the
certification system was important to success
at each of the companies
 important aspects to achieving success when
implementing operator certification was to
provide training i.e. on-the-job training to allow
use of the new skills

6. 3 basic principles that every worker
MUST adhere to:
 We do not accept bad work;
 We do not do bad work;
 When we do bad work, we put it aside (or we
follow a pre-established procedure).

7. Work flow with Operator
certification

8. Work Flow without Operator Self
Inspection

9. Setting up a sound quality system
 Many small and midsize manufacturers in
China don’t have a quality system! It is
imperative to put one in place. A good system
includes, among others:
 Reviewing designs and validating that they are
fit for production;
 Ensuring that standard work instructions are
relevant and are followed by workers;
 Identifying and segregating non-conforming
components and products;

10. Analyzing processes for other
types of problems
 When mistake proofing is not enough or not
possible, we favor two other types of
approaches.
 Root cause analysis, followed by corrective
actions and follow-up. It is important to trigger
this action as early as possible.

11. Maintain staff discipline
 Managers need to get out of their office and walk the production
floor, ideally every day. Coupled with visual management
tools (performance boards filled out at every shift, for example), it
allows them to have an idea of what is going on. It is an occasion
to reinforce the importance of discipline and to put pressure on
supervisors and team leaders when necessary. Among others, the
following rules must be followed by everybody:
 We do not accept bad work
 We do not do bad work
 We do not pass on bad work

12. Mistake proofing processes against
human errors
 Humans make mistakes … But the most
frequent human mistakes can be identified and
addressed with three mistake proofing
processes:
 Prevented right where they appeared.
Example: a part that can only be inserted one
way into a fixture.
 Detected right when they appear. Example: a
sensor detects that only 2 out of 3 holes were
drilled, and shows a red blinking light.

13. A Few Basic Principles
 Operator should give attention to the supervisor in case of defect has been
started
 Operator have an attitude to correct the process in stead of producing
defective part
 Give clearance from production supervisor in case defective process is
continued or not take an approval from qa in such case Ask Operator to
operate equipment or questions about the equipment
 Ask questions but don’t disrupt work activities
 Take immediate action as needed
 Discuss as a group

14. Operator self Inspection
program
1. Awareness to operator regarding upgrade the responsibility
2. Production supervisors should identify the any gap is observed if
yes remove by Training
3. If necessary help form QA Team
4. Maintenance team should explain the machine start up check
5. QA Team would give a control plan which having product and
process parameters
6. Operator is trained for the product parameters and process
parameters by the production
7. Operator is trained for the NC parts identifications and aware of
the red bin]
8. Operator is awarded for the in process inspection formats how to
filled up by qa

15. Operator self Inspection
program; Cont.
9. Operator is allowed for the self inspection activity
10 production also supervisor and qa I/C ensured that in process
inspection has been carried out & defective parts has been recorded in
the daily production report by keeping material as per defined areas
11. Production head has maintained the in process inspection record for
at least one year

16. Process audit
• QA would declared the process audit plan as
per machine process wise
• Conduct the process audit as per report by
process auditors –production
supervisor/quality assurance
• High light to management in case of NC
• If discipline issue has been noticed involve
plant head to sort out

17. What to Expect After
a Self Inspection
 Completed form should be
turned in immediately.
 Assign responsibility to
individuals to make corrective
actions
 Determine who will do follow-up

18. Always Remember
Between inspections, have
method for employees to make
suggestions when they see
Defective part

19. Team Commitment; 5Parts self
inspection first phase on 13th June 22
n
o
action Responsibility Target date
1 Instrument gauges fixture issue system as per section
wise
Potwade,Rahan
e Hari
10th June
2022
2 Operator training for report writing ,measurement And skill
matrix updates for the existing machine operators
All production
supervisors
11th June
2022
3 System for the sales order for the proto part for sales
order is to be started prodcutinosed
Vikas sir MKT&
Project leaders
8th June 22
8 Highest Volume repeated part identification and circulate
via e mail five parts covering all mfg operations
Sonu Bhagat 7th June
2022
9 Process plan documents released for the five parts in
which present format needs to be modified in line with
usage on the shop floor
Shrise .Ulhas
kavathekar
7th June
2022
9 Released for the productionised control plan on the shop
floor along with inspection report
Rahul 11th June
2022