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Final step in the design of a process, it will validate the “invoice” of the project.


The receipt of a new process is an important step. It has a stake in validating all the design work and the ” Invoice “. We must be rigorous in the validation tests if we do not want to “grind” the equipment during production.

1-Perform a pre-production audit

1.1 Preparing the Test

First phase of the reception, we will prepare the test of validation of the process. For this, the personnel who will perform the test must be trained to the new equipment and above all must follow the instructions of the test: respect of the Simogramme, ” standard ” allure, quality control carried out…

To observe what is happening, we will set up a time Keeper to check the actual times with the schedule of specifications and 1 or 2 observers who will have the task of evaluating the micro-stops, discards and noting the different Muda they see. We’ll give them some documentation.

Last point, we need to make sure that we have enough raw materials for the entire duration of the test. A surcharge of 10-20% is generally expected for additional testing.

1.2 Unwind the test and debrief hot

The test must take place in the actual production conditions. The staff must go at a ” normalpace , and observers must let them do and not intervene in case of problems (do not help if a Part falls, or rid the work plan for example). The test will only be resumed if abnormal events occur: ” lost ” personnel in the range, not suitable tool…

Once the test is done, the observers and time Keeper will exchange with the operators on what has been observed and the feeling of all. A plan of improvement actions is defined and draft problem resolutions put in place.

2-Perform an ergonomic audit

Thanks to this first test, we see the range of work in real. We will make an observation with an ” ergonomic ” Look to check the different efforts, the angles of the joints… Immediate improvements will have to be made and a plan of action implemented.

3-delete the last Muda

The goal is to eliminate the latest Muda That we observed during the tests. Most often, it will be by transposing manual operations in automatic: transport of parts…

4-building standards

With the operators, we will build the standards of work. These standards must include High quality What are self-control and self-quality matrix.

5 – Create the Automaintenance range

We will create the maintenance and self-maintenance ranges. This work will be carried out with the help of the supplier who tells us the frequencies, the tasks and the products to be used.

6-Validate the FMEA

The work done during the development of the FMEA is to be resealed. We will validate that the actions implemented are effective and that we no longer have critical risks that are not covered.

7-Set up the monitoring plan

Finally, the last step before the production, the implementation of the monitoring plan. In relation to the quality department, we will build the control plans (Sampling Plan, type of control), the means of controls will be validated via the Gage R & R and then we will set up a Control card to follow the Capability of our way.

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