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Where I was prior, we had the PLEX system. It had a robust SPC setup but nobody every set it up properly. 6 months later, upper management just went in and deactivated it. we were actually told to pencil whip data to make it look good. Quality was a no value added department (direct quote from management) and, as long as parts went out the door, nothing else mattered. So, I know what you are going through.
PLEX is an entire company management system, not just SPC, but it might be something your company would be interested in. If set up properly, it can work wonders.
We use PLEX. However, our floor operators are the ones that monitor it. It's really a culture thing that needs to change. Some of the operators care about SPC, but others just put measurements into the check sheet, not really paying attention to the data and enter a cookie cutter note in there when they are flagged.
Are you using all the SPC functions? We would get alerts for everything: Cpk out, too many points above or below nominal, values within a certain zone of the upper or lower limits, etc. We had it set up to require a sign off to proceed. Our issue was that nobody, outside of quality, knew how bad things were. Instead of correcting the process, they just turned off all the SPC alerts. It also didn't help that we were a forging plant. Parts would purposely start out near the high limit on thicknesses and gradually work their way to the low limit as the die wore. This planned die wear would cause all kinds of SPC issues.
Yes we are. However, they can enter a note and continue running. They are looking into adding something in there to force operators to do something about it.
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