Cause: Incorrect Stampings/Workpieces

A workpiece that does not conform to the relevant bill of material, blueprint, specifications, etc.

Description 

The following are examples of incorrect workpieces:

• Production runs consisting of multiple versions of base product, for which part “A” is selected when part “B” is required.
• Workpiece that has not been made correctly.
• Workpiece that is not of the proper design level (revision).

Detection 

Incorrect workpiece may be detected by observing one or more of the following issues:

• Brittle weld
• Cracks & holes
• Excessive indentation
• Expulsion/burn through
• Extra welds
• Inconsistent weld quality
• Interfacial separation
• Mislocated/edge weld
• Missing weld
• Non-round weld
• Poor Class A appearance
• Sheet metal distortion
• Sticking/stuck tips
• Stuck weld
• Undersized weld

Significance 

Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle time; PPH), are all potentially affected by this condition.

Subordinate Causes

• Improper detection of current model (mechanical or electrical failure)
• Improper location of stock material
• Improper revision level documentation on plant floor
• Inadequate training

Note: Also see Damaged Part.