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    Role

    Operator: does this part pass?

    The person at the machine makes more quality decisions than anyone else: whether the part passes, whether it is time to adjust, why the machine stopped. What is needed is the right value against the right limit, the instruction, and not having to write the same thing twice.

    Questions and decisions

    From question to evidence

    Each question needs certain evidence to be answered. Together they lead to what the role needs afterwards.

    1. Question 1: "Does this part pass?"

      Needs: The value against nominal and tolerance limits

    2. Question 2: "Should I adjust now?"

      Needs: The latest values, the instruction and the right gauge

    3. Question 3: "Why did the machine stop, and what should I enter?"

      Needs: A simple way to enter the reason

    Afterwards

    What the operator records becomes the evidence that quality, production and ultimately the customer use.

    Situations

    One shift, four moments

    The questions come in an order. This is how they look during a shift, with the operator's question and decision in each situation.

    1. 01

      At start

      The machine is changed over. The first part decides whether production may start.

    2. 02

      While running

      Parts are measured at the machine. Every value is a small decision: pass, adjust or keep going.

      Every measured value is compared with the tolerance limits for that particular characteristic. If it is outside, the value needs a note and the gauge used, otherwise the deviation cannot be investigated afterwards.

      Is the part accepted, and what has to be kept with the value?

      Illustration · Example data
      LSLNominalUSLDiameter12.00 ± 0.0512.02AcceptedLength48.00 ± 0.1047.97AcceptedWidth8.00 ± 0.057.93Below LSLDepth3.20 ± 0.053.21AcceptedKEPT WITH THE VALUENote: new material batch, re-measureGauge: micrometer, calibrated

      Every value is compared with its own tolerance. A value outside is not just a rejected result: it needs a note and the gauge used, so that it can be investigated and shown afterwards.

      Step by step

      • Four characteristics are measured on the same part. Each characteristic has its nominal value and its tolerance, for example diameter 12.00 ± 0.05.
      • Diameter (12.02), length (47.97) and depth (3.21) are within tolerance and accepted.
      • The width is measured at 7.93, below the lower tolerance limit (LSL) 7.95.
      • A note on what happened and which gauge was used is saved with the value, so that the deviation can be investigated and shown afterwards.

    3. 03

      When the machine is down

      The reason is easiest to enter while it is still known.

    4. 04

      When the value is questioned

      The same part gives different values depending on who measures.

    Other roles, same situations

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