Developed by: Baqar Hasan 03/14/13 Rev. 01

2

Objectives

On completion of this course, you will be able to:

• Identify the defects • Identify places in your work area where you

can help prevent defects• Test ( 5 questions, 80% passing marks)

3

Almost all defects are caused by human errors.

There are at least ten kinds of human error.

• Forgetfulness: Sometimes we forget things when we are not concentrating.

Safeguards: Alerting operator in advance

or checking at regular intervals

• Errors due to misunderstanding: Sometimes we make mistakes when we jump to the wrong conclusion before we are familiar with the situation.

Safeguards: Training, checking in advance, standardizing work procedures

4

• Errors in identification: Sometimes we misjudge a situation because we view it too quickly or are too far away from it to see it clearly.Safeguards: Training, attentiveness, vigilance

• Errors made by amateurs: Sometimes we make mistakes through lack of experience

Safeguards: Skill building, work standardization

• Willful errors: Sometimes errors occur when we decide that we can ignore rules under certain circumstances.

Safeguards: Basic education and experience

5

• Inadvertent errors: Sometimes we are absentminded and make mistakes without knowing how they happened.

Safeguards: Attentiveness, discipline, work standardization

• Errors due to slowness: Sometimes we make mistakes when our actions are slowed down by delays in judgment.

Safeguards: Skill building, work standardization

• Errors due to lack of standards: Some errors occur when there are no suitable work instructions or standards.

Safeguards: Safeguards: Skill building, work standardization

6

• Surprise Errors:

Errors sometimes occur when equipment runs differently than expected.

When working on hot or rush jobs

Safeguards: TPM, work standardization• Intentional Errors: Some people make mistakes

deliberately. Crimes and sabotage are examples.

Safeguards: Poka-yoke methods

7

2. What are the Sources of DefectsThere are various types of defects. In order of importance

these are:• Omitted Processing• Processing Errors• Errors setting up work pieces

• Missing parts• Wrong parts• Processing wrong work piece• Misoperation• Adjustment error• Equipment not set up properly• Tools and jigs improperly prepared

8

Exercise

What kind of error?

DIESEL

What kind of error?

What kind of error?

9

• PEM Nuts -DOCO missing a stand-off• Extra Hole• Missing documentation -Certs, FAIRs• Machining Work Steps• Threads - center thread rivet missing• Label• Card Guides• Simulator GPU bracket missing• Hash marks• Cutout• Panel lock• Screw/Spring on RAC Bracket

Missing Parts, Process Steps, Documentation

10

Parts Mix-up

• Wrong type of standoffs used• Wrong type of Screws• Wrong labels used

11

Incorrectly Worked Upon Parts

• Spot weld diameter• Spot weld pattern• Hole not chamfered• Wrong artwork• Uniform paint thickness not achieved• Cutout for connector in wrong position• Forming defect – cover wider on one side• Not machined completely• Wrong hole position on HD Bracket• Bad base console-flange formed 0.03 off dimension

12

• Armrest-metal showing through foam• Card cage misaligned• Card guides not fully seated• Cover painted on wrong side• Column cover tab came off• Electrical VSC has bad harness• Electrical-G889, VSC has no video• Cover formed with large taper• Rivet installed on wrong location• Simulator Bracket missing hardware• Contamination-parts not cleaned prior to shipment to

customer• White spots on arm rest POD

Wrong Assembly

13

Wrong orientation

• Rivet installed on wrong location• Form angle error• Wrong hole position on HD bracket• Holes not aligned properly for riveting• PEM nut wrong size/orientation

14

Five most common causes of defects

1. Inappropriate procedures or standards

2. Excessive variability during operations

3. Damaged or excessively variable materials

4. Worn machine parts

5. Simple human mistakes (least predictable of the five)

15

Defect Awareness Test

310307-02

316221-01

15001600-F

314988-06

313742-02

Rac2, Rac1

PN. Defective Y/N Defect

Name:Employee #:

Extra Hole

Forming Error -off by thousands

Wrong sized PEM

Wrong distance from the edge

Holes not aligned when SBP board is installed

PEM Nuts in wrong holes

Defects