Pass Through Characteristics Workshop
It’s embarrassing and expensive to ship defective parts to your customers. How did the defects “escape” from your carefully planned controls? Some of the defects may have come from your suppliers or even sub-tier suppliers, but you don’t notice the problem in your assembly and product inspection. So what can you do to prevent these defects?
Your problem is described by the term “Pass Through Characteristics”. These are the defective product characteristics you do not detect but which your customer finds, much to their annoyance. Examples of Pass Throughs are:
A missing hole which you don’t use, but your customer needs.
Improper heat treatment resulting in early wear.
Improper preparation for coating resulting in peeling paint.
Defective electronic components which work at first, but fail early.
Incorrectly tightened or stripped fasteners.
The Midwest Pass Through Characteristic workshop engages your Team to review your activities and adopt techniques which prevent the errors from getting to your customers. We will review the AIAG CQI-19 Sub-tier Supplier Management Process, and then go further into the theory and practice of Mistake Proofing. And once your Team know how to address one product, they will be able to apply it to all.
The 8 hour workshop includes:
Review of your analysis of what has gone wrong in the past year, including a guestimate of what these errors cost you.
Do a risk analysis based on the flow chart, pFMEA format is preferred. This allows prioritization of the potential problems, with special focus on poor detection or “Pass Through”.
Brainstorm and identify corrective actions to address the high risks. Midwest knows a large number of proven mistake-proofing techniques.
Go out on the shop floor seeing and understanding your production process and how the mistake proofing can be implemented Special attention is paid to the abnormal cases such as rushed orders, incomplete lots, rework.
Revise your Flow Chart, Control Plan and identify which Work Instructions need revised
Develop a detailed plan to implement the changes.
Midwest will follow-up with conference calls at 30, 60, and 90 days to confirm that the plan was executed and the workshop resulted in changes, and that the results show an improvement.