Capability of Visual Inspections

Training
Capability of Visual Inspections

Verification of a Test Process (Procedure 7)
Instructor
Matthias Kohl (CP/TSC10)
Version: 1.0
September 1st, 2014 – training material
Capability of Visual Inspections
Verification of a Test Process (Procedure 7)
Matthias Kohl (CP/TSC10)
September 1st, 2014
1 Intern | CP/TSC10 - Kohl | 01.09.2014 | © Robert Bosch GmbH 2012. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung,
Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Capability of visual inspections
I t d ti
Introduction
• Name Capability of visual

inspections
• Function (department)
• Work experiences in visual inspections?
• Training expectations
Lit t
Literature recommendation
d ti
Literature Author ISBN-13 Price Remark
Bosch Intern– Booklet 10- Capability of Internal ordering
C/QM $10
measurement and test processes possible
Statistical Procedures for Machine and Edgar Dietrich

978-3446422490 $170
Process Qualification Alfred Schulze
Measurement Process Qualification: Gage
Edgar Dietrich
Acceptance and Measurement Uncertainty 978-1569905050 $75
Alfred Schulze
According to Current Standards
Lean Six Sigma and Minitab (4th Edition):
Holly Brook-Piper
The Complete Toolbox Guide for Business 978-0954681388 $55
Marianne Hughes
Improvement
Statistical Methods for Rates and Joseph L.
L Fleiss
978-0471526292 $120
Proportions Bruce Levin
Minitab Cook book Isaac Newton 978-1782170921 $50
B i iinternal
Basic t l ttrainings*
i i *
B ki code
Booking d T i i
Training R
Remark
k
Basics of technical statistics
QM-TQ002-A
discrete (attribute) characteristics
Basics of technical statistics
QM-TQ002-B
continuous (variable) characteristics
Capability of measurement and test processes
QM TQ038
QM-TQ038
(complete booklet 10)
QM-TQ017 Measurement uncertainty
QM-TQ061 qs-STAT/solara basic training
QM-TQ062 qs-STAT/solara
/ advanced training
* Reference to Bosch Training Center (C/BTC) proposal – „ Enhance Competencies - Seminars for Bosch
Bosch-Suppliers“
Suppliers
Capability of visual inspections Input Case-
Studies
Practice
Obj ti
Objectives and
d content
t t Dialog
Knowledge exchange about visual inspections
▸ What is our mutual understanding

g of visual inspections?
▸ Learning by case studies
▸ What is my role within visual inspections?
Practical use and understanding of the capability of

measurement systems
▸ Experience and understand processes and control loops
▸ Collect,
C ll t evaluate,
l t visualize
i li and
d understand
d t dd data
t
Gain motivation for daily work
▸ Start right after the training…
O
Overview
i off the
th modules
d l
Module 2 Module 3
Preparation Th
Theory
Module 1
I t d ti
Introduction
Module 5 Module 4
Supporting software Case studies
(Backup)
A
Agenda
d
Time Subject Referee

Introduction All
09:00 a.m. – 10:30 a.m. Data types, terms and definitions, differences Trainer
among booklet 10 procedures
Basics of visual inspection
p Trainer
10:30 a.m. – 10:45 a.m. = Break =
Getting to know procedure 7 & preparation
10:45 a.m. – 12:15 a.m. Trainer
off practical
ti l case studies
t di
12:15 p.m. – 01:00 p.m. = Lunch=
01:00 p.m. – 02:30 p.m. 1st Team work / discussion Participants
02:30 p.m. – 02:45 p.m. = Break =
02:45 p.m. – 04:00 p.m. 2nd Team work / discussion Participants

04:00 p.m. – 04:15 p.m. Final review and feedback All
Capability of visual inspections Introduction 2 3 4 5
M d l 1 (Introduction)
Module (I t d ti )
1 • Motivation
2 • Terms and definitions
3 • Data types
4 • Diff
Differences b
between procedures
d (Bosch
(B hbbooklet
kl 10)
M ti ti
Motivation
Requirements of the norms*
7.6.1 Measurement system analysis

Statistical studies shall be conducted to analyse the variation present in the
results of each type of measuring and test equipment system. This requirement
pp y to measurement systems
shall apply y referenced in the control pplan.
The analytical methods and acceptance criteria used shall conform to those in
customer reference manuals on measurement systems analysis
analysis. Other
analytical methods and acceptance criteria may be used if
approved by the customer.
* Source: ISO/TS 16949: 2009(E)

2009(E), page 47
M ti ti
Motivation
Requirements of the norms*
16. Control of inspection,

p , measurement and test equipment
q p
...The accuracy of the results from a piece of equipment, evidenced in its
documentation, is of particular importance as inaccurate measurements could
lead not only to non
non-conformance
conformance of an “assured
assured characteristics
characteristics”,, but could
also present a risk when testing quality and safety-relevant characteristics.
* Source: VDA Vol

Vol. 6 (1)
(1), 4
4. edition - 11/2010,
11/2010 page 138
T
Terms and
d definitions*
d fi iti *
…is to check whether the inspected object is within the

Inspect specified dimension and shape.
…is
is to measure the length or angle etc
etc. of an object by using
Measure
a measurement standard
…is to check whether lengths, angles or shapes of the

i
inspected
t d object
bj t are outt off the
th limits
li it (defined
(d fi d by
b gauges),
)
Gauge and whether the measured value is below or above the
limit. The value of deviation will not be measured.
* Source: DIN 1319-1 Basic concepts in metrology / Part 1 – General concepts- 01/1995
D t types
Data t
Data
Discrete Continuous
Binary
y Number Categories
g
Ordinal:
One off two
O t Count/
C t/ N
Nominal:
i l
estimation,
options measurement categories Interval/ proportion:
ranking, row
measured on a scale
Yes/no Number of failures Grades Cycle time of an order in

Machine,, region
g
OK/ NOK i a batch
in b t h scale (A-F)
(A F) [h]
12 Intern | CP/TSC10 | 01.09.2014 | © Robert Bosch GmbH 2012. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion,
Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
D t types–
Data t examples
l ffor di
discrete
t data
d t
• Characteristics have only two values

Binary
y • Yes/No; Start/Stop
• Good/Bad
G d/B d
• Characteristics are described by whole numbers only

• Number of machine failures, customer complaints,
Number misprints on a page, programming failures
f in a software
f
te data
module
• Data is assigned to ranked categories.

Discret
• Characteristic values exhibit a rank order

Ordinal • Distinction between categories is not identical
• Grades (A – F), education (middle school, high school,
college)
D
Categories • Elements are assigned to categories

• Not reasonable to rank categories; describe attributive
data by using a scale
Nominal • Man, woman, child
• Mechanical, electromechanical, electrical
• Colors (blue– yellow – red)
D t types
Data t – examples
l ffor continuous
ti data
d t
• Measurements have the same intervals, but no absolute zero (e.g. Celsius-
s data
temperature scale)
Interval • Cycle time, pressure, filling weight of a packaging unit, speed of conveyer,
Conttinuous
diameter of a turning workpiece

workpiece, soldering temperature
• Same measuring units including absolute zero
Proportion • Reasonable to use ratios: 6m/min is twice as fast as 3m/min

• Velocity, time, length, Kelvin-temperature scale
D t types
Data t
Overview
Measurement
Objective Subjective
“
“measurement”
t” “i
“inspection”
ti ”
Measurement Gauge See Taste
Smell Feel
Listen
MSA Procedures
P d
Bosch booklet 10*
Procedure 7 Procedure 1
Test decisions for
Systematic
discrete and
measurement error
discretized
and repeatability
characteristics
Procedure 6 Bosch booklet 10 Procedure 2

Test decisions for Capability of Repeatability &
discretized reproducibility
continuous measurement and test p
with operator
characteristics processes influence
Procedure 5
Stability Procedure 3
(Long-term behavior Repeatability &
of a measurement reproducibility
Procedure 4 without operator
system)
Linearity i fl
influence
*BGN:
BGN: Organization -> Corporate Functions -> C/QM -> Guidelines & Standards -> Bosch Booklets
Capability of visual inspections 1 Preparation 3 4 5
M d l 2 (Preparation)
Module (P ti )
1 • Optical illusion
2 • Basic requirements / instruction for appraisers / eyesight test
3 • Workplace design
4 • St d di ti / lilimitit sample
Standardization l catalogue
t l
O ti l illusions*
Optical ill i *
Let‘s start with a simple example.

example There is more to see than the hills at first
glance. What else can you discover?
* Source: http://www.igmetall.de;
http://www igmetall de; (05
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
The last one was easy? So

So, how about this one?
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
Find the hidden face in the coffee beans.

beans Once you
you‘ve
ve found it,
it it seems to be so
obvious.
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
Which orange cycle is bigger? (The left or the right one?)
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
Compare these two tables. What is the difference in size and shape between both
table tops?
Now measure the table tops with a ruler!
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
Decide quickly at first sight: Which of the two distances between the arrows is
longer, the right or the left one?
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
Two pictures of a
friendly-looking
President Obama?
(05.12.2013)
12 2013)
O ti l illusions*
Optical ill i *
If the pictures are upside-

down, both seem to be
normal.
But if you turn them right,
you can see that
th t the
th mouth th
and the eyes are deformed.
(05.12.2013)
12 2013)
B i requirements
Basic i t
Non-destructive testing–
Qualification and certification of NDT personnel
English version EN ISO 9712:2012 (ISO/TC 135/SC 7; FDIS 9712)
… When there is no requirement in legislation, in standard or in the order for

certification of NDT personnel, it is for employers of such personnel to decide
how to assure themselves that they are competent to do the work assignments.
assignments
Thus, they may employ people who are already certified or they may apply their
own expertise so as to assure themselves that their employee has the necessary
competence.
t In
I this
thi llastt case, prudent
d t employers
l wouldld no d
doubt
bt use this
thi
International Standard as a reference document.
* Source: EN ISO 9712 - June 2012 - page 5
Methods
M th d according
di tto international
i t ti l norm
EN ISO 9712:2012
* Source: EN ISO 9712 - June 2012 - page 11
T i i llevel*
Training l*
(Visual testing; VT) NDT Level 3
• NDT experience: 12 months
NDT Level 2 • minimum duration: 24h
•NDT experience: 3 months
NDT Level 1 supervise all level 1 and level 2
• minimum duration: 24h duties, full responsibility for NDT
• NDT experience:
i 1 month
th
equipment and staff, approve
Select the equipment, prepare process introduction,…
• minimum duration: 16h
process instructions, verify
Set up the equipment, perform the equipment settings, train & guide
tests, record and classify the staff below level 2, …
results in accordance with
documented criteria, report the
results, …
E
Eyesight
i ht ttestt (at
( t least
l t once a year))
* In order to complete the level one needs to pass a written and practical exam
Acronym (NDT): Non
Non-destructive
destructive testing
E
Eyesight
i ht test
t t
(Example – red-green color blindness)
E
Eyesight
i ht test
t t
(Example – visual acuity)
Snellen Chart Tumbling E-Chart Landolt C-Chart
E
Eyesight
i ht test
t t
(Example – contrast sensitivity)
Pelli-Robson Chart Contrast Sensitivity Chart
W k l
Workplace design
d i
Which requirements does an inspection workspace
have to fulfill?
Employee-specific
f Product-specific
f Workplace-specific
f
•Source: Ergonomics guidebook for manual production systems; Version 3.0; Bosch Rexroth AG (01/2012)
Gestalten von Sichtprüf
Sichtprüf- und Arbeitsplätzen (E.
(E Maurer; CP/TSC10)
E l
Employee-specific
ifi design
d i
Questions
 How long is the working time? (piece rate vs. time rate)
 How long is the total time of the visual inspection? (breaks)
 Is the required information available?
 Limit sample catalogue (in view field / in reaching distance)
 Master sample pieces chosen for the training
 Is the visual inspection procedure described and specified in detail?
 How is the effectiveness of the appraisers?
 Each appraiser without standard
 Each appraiser vs. standard
 Between appraisers without standard
 All appraisers vs. standard
 Risks of the inspection (false alarm rate & miss rate)
E l
Employee-specific
ifi ddesign
i
Example - view field
A continuous change of view angles > 45º is very stressful and tires out your
eyes.
E l
Employee-specific
ifi ddesign
i
Example - view field
Display
A
Assembly
bl site
it
Unfavorable layout of displays which Optimal layout of displays with a

can lead to neck pain.
pain change of view angle less than 45 ° -
less stressful for your neck.
E l
Employee-specific
ifi ddesign
i
Example - reach area
3 reach zones:
C)) Center of work,, two-handed zone:

Both hands work in view field.
(assembling place, view field, visual inspection)
B) Extended reach zone:
zone
Area to put parts and tools which are often grabbed with one hand.
A) One-hand zone:
Occasional handling, e.g. for transferring parts to the range of movement
P d t
Product-specific
ifi ddesign
i
Questions
 How many parts are needed for one shift/day?

 How much time does the visual inspection of a single part take?
((characteristics/cycle
/ y time )
 How many visual appraisers are needed to check the daily production?
 How small are the characteristics that are inspected?
(Can they be detected with the naked eye?)
 Materials dimensions
Materials,
W k l
Workplace-specific
ifi ddesign
i
Questions
 Is there sufficient light available (Lux-value)
 How large is the range of movement?
 Is there a clear separation of parts to be inspected, the already inspected parts
and the NOK parts?
 How much does the visual inspection tire the eyes out?
 Specified standardization level
 Consistent inspection process
 Adequate
d di
distance ffrom eye to the
h iinspected
d object
bj ffor an optimal
i l fifixation
i
 Flow of goods (e.g. from the left to the right)
 Documentation forms
W k l
Workplace design
d i
Example - luminosity
The appropriate luminosity for a particular task(Lux-value) prevents mistakes
p
and improves the effectiveness.
Recommended Lux-value for an inspection place is 1000 to 1500 Lux*.
Further criteria are e.g. light color or desk pad (table) color.
* The lower limit at a office workplace is approx. 500 Lux. (Lower limit for the rest of the office: 300 Lux)
Source: Bildschirmarbeitsverordnung - BildscharbV vom 4. 4 Dezember 1996 (BGBl(BGBl. I SS. 1841
1841, German law)
W k l
Workplace design
d i
Example - posture
The correct posture can help to avoid damages of the intervertebral disc.
Force
Force
PCB
Hand rest
Intervertebral
disc Intervertebral
Vertebra disc Vertebra
W k l
Workplace design
d i
Example - working height
High frequent repeated activities at a higher position than the heart have
negative effects on blood circulation and health which results in inefficiency.
inefficiency
W k l
Workplace design
d i
Example - flexible work equipment
To maintain performance and promote productivity, all work equipment around
the workstation must be precisely adjusted to the employee and the activity.
N
Negative
ti E Example
l – limit
li it sample
l catalogue*
t l *
Limit sample catalogue Problems
• 4 different limit sample catalogues
were in use (supplier, plant,…)
• No uniform failure mapping

(from the deviation to the inspected
characteristics)
h i i )
• Rejected inspection characteristics by

supplier
• Undefined interfaces
(development, PQA, TSC, supplier)
Consequences
• up to 40% false alarm rate
• up to 30% miss rate

* Source: NGI
NGI- injector elastomeric Task Force (limit sample catalogue workshop)
N
Negative
ti E Example
l – limit
li it sample
l catalogue*
t l *
ffailure
il
catalogue with
64 pages!
580 failure
codes!
*Source:
Source: gear pump - Task Force
Ch kli t for
Checklist f creating
ti limit
li it sample
l catalogues
t l
• Transfer of customer / functional requirements
q to inspection
p requirements
q
(e.g. definition of critical area, functional description,… )

• Definition of inspection conditions


(e.g. distance, luminosity, magnification,…)
• C
Categorization
t i ti off good d/bbadd parts
t
(e.g. 4 different failure states from „good to bad“)

• Basic structure / standardization / documentation


(e.g. according to failure place and type)
• Validation of the limit sample catalogue – using MSA procedure 7


(Are all failure types / indications correctly evaluated?)
• Release or optimization of the limit sample catalogue if required 

(e.g. new evaluation of failure types, provide distinct sample,…)
Capability of visual inspections 1 2 Theory 4 5
M d l 3
Module
Theory – Procedure 7
1 • Introduction & basic requirements
2 • Planning & implementation
3 • Analysis
4 • C
Capability
bili assessment
5 • Stability monitoring / repetition of capability studies
6 • Case study (Pareto – analysis)
P
Procedure
d 7
Introduction
Objective:
Verification of the capability of a test process regarding unambiguous test
decisions when testing discrete characteristics.
„ p
„A perfect attributive measurement system
y would never reject
j an OK p
part and
never accept a NOK part“
Basic Requirements:
• Provide reference standard (limit sample catalogue)
• Categorizing (e.g. good/bad; 1,2,3;...)
• Prepare reference lot (master parts)
Lot size:
100-200 parts recommended, according to the AIAG MSA/ Bosch-Booklet at least 50
parts are required
p q
Composition:
All attributes relevant for the test must be included in representative ratio in the
reference lot, i.e. all error characteristics that are to be identified by the test process
(good/bad parts and limit samples)
The
h importance off ffailure
l categories can e.g. b be d
derived
d ffrom a ffailure
l Pareto chart.
h
(e.g. 2-4 parts per failure type, in relation 25 bad/ 25 good parts)
Identifiabilit
Identifiability:
Each reference part of the lot must be uniquely identifiable so that the
respective data can always be allocated correctly.
(
(e.g. complex
l number b codes)
d )
=> only authorized staff, but not the appraisers, can identify the reference parts
• no labeling of defect area
• no grouping of good & bad parts
(e.g.: part-no.: 1-25 good / 26-50 bad)
P
Procedure
d 7
Implementation
Type of visual inspection:
With influence from the operator (manual visual inspection):
=> This
Thi applies
li to allll appraisers
i at the
h quality
li gate!!
- 3 appraisers with 3 runs are recommended, at least 3 appraisers and 2 runs are
required (effort: 3 appraisers x 2 runs x 50 parts => 300 inspections)
Without influence from the operator (automatic sorting machine):

- at least 6 runs
(effort: 6 runs x 50 parts => 300 inspections)
Additional hints for manual visual inspection:

• The order of samples has to be randomly chosen for each run.
• The appraisers have to conduct the inspection independently without being
influenced by colleagues.
colleagues
• The inspection has to be accomplished under the same conditions as in the serial
production. (cycle time, aids & visual inspection catalogue,...)
P
Procedure
d 7
Analysis
The unambiguousness of test decisions is analyzed with the help of pair-wise
agreements of the individual ratings.
ratings
The parameter [] (“kappa”) is used as a quantitative measure:
= Observed non-random agreements

P
Possible
ibl non-random
d agreements
t 1
P
= Obs
1-P
Exp
PExp
-P
* Detailed calculation methods are presented in Bosch booklet 10 in Appendix G.
Att ib ti measurementt systems

Attributive t
Example: 2 appraisers and 2 categories*
g
Number of decisions [N]:
appraiser 1 N = GG + BB + BG + GB
good bad
Relative observed agreement [Pobs ]:
GG  BB
PObs 
good
GG GB G2 = GG + GB N
er 2
Hypothetical probability of chance

appraise
agreement [Pexp ]:
G1 G 2 B1 B 2
PExp  x  x
BG BB
bad
N N N N
B2 = BG + BB
Ob  PExp
Kappa Index [] =
PObs E
G1 = GG + BG B1 = GB + BB 1  PExp
* Equations according to Cohen

Cohen´ss Kappa
Kappa-Statistics
Statistics
Att ib ti measurementt systems

Attributive t
Example: 2 appraisers and 2 categories*
g
Number of decisions [N]:
appraiser 1 N = 40 + 30 + 15 + 15 =100
good bad
Relative observed agreement [Pobs ]:
40  30
PObs   0,7
good
GG=40 GB=15 G2 = GG + GB 100

er 2
Hypothetical probability of chance

appraise
agreement [PExp ]:
55 55 45 45
PExp  x  x  0,505
BG=15 BB=30
bad
B2 = BG + BB 100 100 100 100
Kappa Index [] =

0,7  0,505
 0,394
G1 = GG + BG B1 = GB + BB 1  0,505
* Equations according to Cohen

Cohen´ss Kappa
Kappa-Statistics
Statistics
P
Procedure
d 7 - Analysis
A l i
Fleiss' Kappa - Statistics
The analysis comprises the following comparisons of the following parameters [] :
Within • C
Compare allll ttestt runs off each
h individual
i di id l appraiser
i without
ith t
appraiser comparing to the reference (repeatability).
Between • Compare all test runs of all appraisers without comparing

appraisers to the reference (reproducibility).
Each
• Compare all test runs of each individual appraiser to the
appraiser
vs reference
vs. reference.
All
appraisers • Compare
p all test runs of all appraisers
pp to the reference.
vs. reference
* The analysis according to [AIAG MSA] does not intend “within-appraiser” comparisons and comparing “all test runs of all
appraisers to the reference”
reference is not possible.
possible
A B C
A A A B B B C C C
Within
appraiser = = = = = =
1 2 3 1 2 3 1 2 3
Run Run Run
A-B-C
ABC
A B C A B C A B C
Between
appraisers = = = = = = = =
1 1 1 2 2 2 3 3 3
Run
A-R B-R C-R

Each
E h A A A R B B B R C C C R
appraiser = = = = = = = = =
vs. reference 1 2 3 1 2 3 1 2 3
Run Run Run
A-B-C-R
All A B C A B C A B C R
appraisers = = = = = = = = =
vs. reference 1 1 1 2 2 2 3 3 3
Run
P
Procedure
d 7
Capability assessment
Internal Additional customer specifications*
Kappa Percentage Percentage

Decision:
bad as good good as bad
Test process is… [ ] (miss rate) (false alarm rate)
…capable ≥0,9 ≤2 % ≤5 %
…conditionally capable , ≥0,7

0,9> , ≤5 % ≤10 %
…not capable <0,7 >5 % >10 %
If the
h test process is
i conditionally
di i ll capable
bl or not capable,
bl iit must b
be improved
i d by
b
taking suitable measures (e.g. instruction of test personnel, correct handling,
changes of construction, alternative test equipment).
* A.I.A.G. – Chrysler Corp., Ford Motor Co., General Motors Corp. - Measurement Systems Analysis, Reference Manual, 3. Edition
P
Procedure
d 7
Stability monitoring / repetition of capability studies
Regarding the capability of test processes there are no recommendations for long term
stability checks.
Using the np-charts or p-charts on a regular basis is recommended. However, the
effort for a stability monitoring (procedure 7) is similar to a repetition of the case study.
A repetition of the capability study should be considered:
• in the case of additions to or significant changes of the reference standard
(limit samples catalogue)
• if basic conditions of the test process have changed
• after changes of the appraisers (e.g. new staff members)
• in the case of technical changes
g of the test system
y (e.g.
g setup, software)
• after maintenance of the test system or components of the test system
•…
Visualization
Objectives:
 analyze data by using a graphical tool
 gain
i an overview
i on graphical
hi l ttools
l
Remark:
The type of the data (discrete or continuous) is crucial for the visualization of
th data.
the d t
Pie chart, circle diagram or Pareto chart are suited best to discrete data, while
continuous data is better presented in a bar chart (histogram).
(histogram)
P t chart
Pareto h t
 The Pareto chart emphasizes the important discrete data and sets priorities
 The focus lays on a few root causes which have a great impact
(80 : 20 rule by Vilfredo Pareto (1848–1923))

 The category “others“ (if any) should be kept small
* Source: http://www.crp-infotec.de
http://www crp-infotec de ; (16.01.2014)
(16 01 2014)
P t chart
Pareto h t
 In the Pareto chart values are represented in a descending order by bars (e.g.
defects) The cumulative total is represented by the Pareto curve (prioritization)
Visualization in Minitab 17
P
Preparing
i ththe Pareto
P t chart
h t
Total list Ordered by frequency Pareto chart
Type of defect
Chip Bend
Dent Peel
Scratch Chip
Bend Chip Damage Counts
Peel Scratch
p
Chip Scratch Scratch 351
Chip Scratch Chip 49
Peel Chip Bend 19
Scratch Peel
Scratch Dent Other 4
Chip Scratch
Bend Bend
Scratch Dent
Scratch Scratch
Scratch Bend
…..
P t analysis
Pareto l i
Exercise
The assembly of engines of a specific series type requires several components.The
failures found during the inspection are documented in a failure collection sheet by the
inspection personnel.
personnel
In connection with the monthly quality analysis, the foreman is responsible for
statistical analysis of the detected failures.
failures Especially for the production plant,
plant it is
important to focus on the failure types with a high impact in order to efficiently reduce
the failure costs.
Please find the list with the detected failures and the respective costs in order to
correct a specific failure in your work sheet. Please analyze the provided data and
visualize your results by using the Pareto chart.
Pareto charts:
 Failure frequency => waterfall diagram

 Failure costs=> bar diagram
g
P t analysis
Pareto l i
Solution
Failure frequency Failure costs

(waterfall diagram) (bar diagram)
Top
p 4 – Topics
p are
responsible for approx.
80% of the total cost
Capability of visual inspections 1 2 3 Case study 5
M d l 4 (Case
Module (C study)
t d )
1 • Introduction / objectives
2 • Implementation
3 • Data analysis and intepretation
C
Case study
t d
Obj ti
Objective O
Operational
ti l definitions
d fi iti and
d exercise
i regarding
di procedure
d 7
You are responsible for the outgoing (manual visual inspection) at m&m‘s®.
Approach
The product is defective if there are cracks on the surface or if the letter
„m“ is not completely legible.
• Build a team of 5 colleagues

• Pick 3 m&m’s® per person and develop together a limit sample catalogue
for ‘‘crack“ and “letter“
• Put the m&m‘s® aside
• Assign a game leader, an expert and three appraisers
• The game leader randomly chooses 25* m&m‘s®
• Now sort out the m&m‘s® by using the worksheets given on the next
pages. Please remember to change the inspection order between each
trail/ round.
• Calculate for 3 appraisers and 2 trials the “relative observed agreement
[Pobs ]“
Time limit
60 minutes
* Only for practice only 25 parts are chosen.
chosen (according to booklet 10 at least 50 parts!)
T
Team workk – Procedure
P d 7*
Collection sheet (example for [POBS])
Between All appraisers vs.
Known Appraiser 1: Appraiser 2: Appraiser 3:
Test items appraisers standard
standard
Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2 yes/no yes/no
1 good good good good good good good yes yes
2 bad good bad bad bad bad bad no no
3 good bad good bad good good good no no
7 good good good good bad good good no no
8 bad good bad bad bad bad bad no no
9 good bad bad bad bad bad bad yes no
10 good good good good good bad bad no no
11 bad bad bad bad bad bad bad yes yes
14 good good good good bad good good no no
15 bad good bad bad bad good good yes no
19 good good bad good good good good no no
20 bad bad bad bad bad good good no no
22 good good bad bad bad good good no no
25 bad good good good good good good yes no
Within appraiser 19/25=> 76% 22/25=> 88% 25/25=> 100% 64% 52%
Each appraiser vs.

17/25=> 68% 19/25=> 76% 20/25=> 80%
* For practice purposes only 25 parts are chosen.
standard
(according to booklet 10 at least 50 parts!)
T
Team workk – Procedure
P d 7*
Collection sheet - [POBS]
Between All appraisers vs.
Known Appraiser 1: Appraiser 2: Appraiser 3:
Test items appraisers standard
standard
Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2 yes/no yes/no
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Within appraiser /25=> /25=> /25=>
Each appraiser vs. * For practice purposes only 25 parts are chosen.
/25=> /25=> /25=>
standard (according to booklet 10 at least 50 parts!)
T
Team work:
k Attributive
Att ib ti MSA (Procedure
(P d 7)
Objectives The application of Kappa - Index []
Approach • Pick 36 samples with different scratch images

(“speedometer-element“, e.g. small scratches to large scratches)
• Define 6 crack categories (e.g. very good to very bad)
• Choose reference standards for the 6 categories
g
• Assign 3 appraisers
• The appraisers assign the trial 30 samples into the 6 categories
twice. In each trial the inspection order must be changed
• Write down the results in the Excel sheet:
„ Type7_EN_RefDisc_0030_003_002_006.xls „
Sheet: „Test Data“
• Please calculate the Kappa - Index []
Time limit 60 minutes
* For practice purposes only 30 parts are chosen.

chosen (according to booklet 10 at least 50 parts!)
Ch kli t
Checklist
• The measurement system is well-defined
(continuous or discrete measurement)

• Scale and frequency are adjusted

(e.g. limit sample catalogue, scale interval, sample size,… )

• Measurement equipment is well-defined and documented

(e.g. certification, approval according to procedure 1)

• Th
The measurementt system
t has
h been
b analyzed
l d
(depending on data type: Gage R&R, Kappa-Index…)

• The measurement system is capable

(Measurement system variation is acceptable)

• Failure documentation is aligned to problem solution

(e.g. Pareto analysis for prioritization, control charts for control)

Capability of visual inspections 1 2 3 4 Software
M d l 5
Module
Software support
1 • Minitab 17
2 • Q-DAS
Q DAS (QS
(QS-Stat
Stat / Solara ME10)
C t t – Minitab
Content Mi it b introduction
i t d ti
1. Introduction of Minitab
1 1 Main menu and function keys
1.1
2. Session window / work sheet
3. Data input
4. Save data The statements on the following
5. Pull-down menu pages are a short summary of the
5 1 File
5.1 MINITAB handbook.
5.2 Edit
5.3 Data In order to learn more about
5.4 Calc (calculation) MINITAB the "Help" function is
5.5 Stat (statistic) recommended.
5 6 Graph
5.6
6. Pareto chart
7. Attributive measurement analysis
7.1 Assessment agreement
7.2 Assessment agreement (assistant)
7 3 False rate and miss rate alarm
7.3
1 Introduction
1. I t d ti off Minitab
Mi it b
Basic information
A MINITAB project
j t always
l includes
i l d :
 Session window: Documentation of the entire work
 Work sheet: Data,

, you
y are working g with
 Project manager: Information about everything that belongs to the project
Wh created,
When t d a MINITAB project
j t includes
i l d also
l :
 Graphics
 Report
p p pad
1 1 Main
1.1 M i menu and
d ffunction
ti keys
k
File Editor
Open, save, print, etc. Formatting columns,
columns functions for the
Edit Session window, programming, etc.
Copy, paste, links, etc.
Tools
Data Link to other programs, preferences,
Rearranging of data that are options, etc.
already in the worksheet
Calc Window
Wi d
Calculate and generate Switching between windows
random data
Help
Stat Help, Learning assistant, StatGuide
Statistical tools, quality tools,
graphics with calculation Assistant
Graph Guided standard analyzes
Illustrations, graphics with
calculation
1 1 Main
1.1 M i menu and
d ffunction
ti keys
k
1 2 3 4 5 6 7 8 9 10
1. Open project (not worksheet) 7. Previous andd next commandd

(Operation in the Session
2. Save project (all edited and created window)
content)
8. Search
3. Print window
9 Cancel
9.
4. Cut / copy / paste
10.Help / StatGuide
5. Undo// redo
The StatGuide explaines with
6. Edit last dialog reference to examples, how the
results should be interpreted
Reopen the most recently used
dialog to return the command or
modify settings
1 1 Main
1.1 M i menu and
d function
f ti keys
k
1 2 3 4 5 6 7 8 9 10 11 12
1. Session folder 6. ReportPad folder
Manage session window output Use to create, arrange, or edit
reports of project work
2. Worksheets folder
View summaries of worksheet 7. Related Documents folder
information Contains a list of program files,
documents, or internet URLs that
3. Graph folder are related to your Minitab project
Manage all the graphs you have
created 8. Design
4. Info 9 Session window
9.
Show information in the columns of the
current worksheet 10. Current data window
5 History
5.
11. Project manager
Show the command history folder
Use to repeat complex command 12. Close all graphs
sequences
2 S
2. Session
i window
i d / workk sheet
h t
Session window:
The Session window displays the text output
generated by your analyses and other work.
Work sheet:
In Minitab, all the data associated with a particular
data set are contained in a worksheet.
3 Data
3. D t input
i t
The data can be entered into the worksheet in different ways:
 Manual entry
 Copy and paste from other programs (Excel, Access)
 Direct opening of files to be imported
4 S
4. Save data
d t
Projects include the complete Worksheets include only the

analysis of the data: collected data :
Fil extension:
File t i *
*.mpjj Fil extension:
File t i * t
*.mtw
5 P
5. Pull-down
ll d menu
 The first four pull-down

pull down menus (File to Calc) mainly include the basic
functions of Minitab
 The pull-down menus “Stat” and “Graph” include Minitab specific tools that
are required to apply statistical analysis
51P
5.1 Pull-down
ll d menu : File
Fil
File organization
Print
Recently opened files
52P
5.2 Pull-down
ll d menu : Edit
Data sheet organization (like in Excel)
53P
5.3 Pull-down
ll d menu : Data
D t
Edit worksheets
Sort data
Delete rows
Numerical / Text
54P
5.4 Pull-down
ll d menu : Calc
C l
Calculator
Generation of random data and distributions
56P
5.6 Pull-down
ll d menu : Stat
St t
57P
5.7 Pull-down
ll d menu : Graph
G h
6 P
6. Pareto
t chart
h t
Stat > Quality Tools > Pareto Chart
Select this option if

data is entered
d d in a
column
6 P
6. Pareto
t chart
h t
Select “frequencies” when
the data in the worksheet is
available as table
7 Attributive
7. Att ib ti measurementt analysis
l i
In the following chapter, the evaluation of an attributive MSA with the Minitab
program is shown exemplarily.
7.1 Assessment agreement

7.2 Assessment agreement (assistant)
73F
7.3 False
l rate miss
i rate alarm
l (
(assistant)
i )
Data example:
In the visual inspection of scratches we distinguish between four different failure
types. The inspection is performed by four appraisers in exchange.
g
In order to investigate the attributive measurement system
y an expert
p has
selected ten samples and classified them according to their failure types. Each
appraiser should independently inspect each sample twice.
7 1 Assessment
7.1 A t agreementt
Advice:
The “Attribute Agreement Analysis”
focuses on the following variables which
are evaluated by the Fleiss-Kappa-
method:
binary
e.g. good - bad, NOK - OK, available –
nott available
il bl
ordinal
e.g. ranking order or categories
(1, 2, 3, 4,…)
71A
7.1 Assessmentt agreementt
71A
Fleiss’ Kappa
pp Statistics
71A
Fleiss’ Kappa
pp statistics
72A
(Assistant)
Advice
Advice:
The following variables can be analyzed
with the help of the assistant
“M
“Measurement t System
S t Analysis(MSA)”:
A l i (MSA)”
binary
e. g. good- bad, NOK - OK, available - not
available
Caution:
Fleiss-Kappa-method
Fleiss Kappa method is not possible.
possible
(only direct observed agreement, P0)
72A
(Assistant)
72A
(Assistant)
7 3 False
7.3 F l rate
t & miss
i rate
t alarm
l
(Assistant)
C t t – Q-DAS
Content Q DAS introduction
i t d ti
1. Create a new file
2. Defaults and creation of new data sets
3. Data structure
3 1 Parts mask
3.1
3.2 Characteristics mask
3.3 Values mask
4. Attributive Measurement Analysis
4.1 Select Procedure
4 2 Create data
4.2
4.3 Evaluation
4.4 Report
5. Key commands
1 Create
1. C t a new file
fil
• Icon bar
• Menu/File/ New
• The appearing menu depends on the selected module!
2 Defaults
2. D f lt and
d creation
ti off new data
d t sets
t
 When changing the specifications all new characteristics will be created according
to these specifications.
 The specifications should be consistent with the majority of processes.
 Especially other sample variables and measurement variables and characteristic
numbers can be specified.
 Tolerances should not be specified!
3 D
3. Data
t structure
t t
 E h data
Each d t sett is
i described
d ib d by
b administrative
d i i t ti information.
i f ti
 Three levels:
1. Part-level
2. Characteristic-level
3 Value-level
3. Value level
 Part-level can be seen as “part type description”
 On the characteristic-level tolerances are specified
 Value-level shows the measurement value and additional
data.(e.g. inspection date or/and responsible appraiser)
 The data structure is displayed by the following icon:
 “Parts / characteristics list”
31P
3.1 Parts
t maskk
 All iinformation
f ti should
h ld b
be entered
t dh here:
That describes the end product (the main unit)
3 2 Charateristics
3.2 Ch t i ti mask k
 All information that describes the characteristics
(especially the tolerance limits and the nominal size!) should be entered here:
3 2 Characteristics
3.2 Ch t i ti mask
k
Input of ISO-tolerances (fits)
By double clicking the field which shows a value within the tolerances, an input
assistance will be opened (input assistance ISO 286 ).
Double click
33V
3.3 Value
l mask
k
Measurement values and additional information should be entered in the
value mask:
 Value
 Attribute
 Charge
 Appraiser
 ...
33V
3.3 Value
l mask
k
Linear transformation
 With the help of the linear transformation the input duration and possible input
mistakes by the operator can be substantially reduced.
 Th lilinear transformation
The t f ti should
h ld onlyl be
b applied,
li d if th
the d
data
t changes
h after
ft ththe
decimal point, or if “+” and “–” can be read from the dial!
Practical application:
• The dial gauge shows differences to
a data point
• Manual input with a lot of
measurement values
• Data must be
b converted d ffirst b
before
f
entering
4 Attributive
4. Att ib ti Measurement
M tAAnalysis
l i
The following section presents an example of an attributive MSA by using the

SOLARA V10 p program
g ((developed
p byy QS-Stat).
)
4.1 Strategy selection

4 2 Create data
4.2
4.3 Evaluation
4.4 Report
Data example:
When visual inspecting scratches, different failure types / images (25 bad parts
andd 25 good d parts)
t ) can b
be di
distinguished.
ti i h d The
Th iinspection
ti willill be
b performed
f dbby
three different appraisers in exchange.
In order to investigate the attributive measurement system, an expert chooses 50
samples and assigns them to the category “good” (1) or “bad” (0).
Each appraiser should independently inspect each sample three times.
4 1 St
4.1 Strategy
t selection
l ti
NEW > Type-7 Study Default (Type-7 Study)
Click on default to
adjust different pre
pre-
settings depending on
the case study.
These settings are the

default settings for all
created characteristics
of the corresponding
type of characteristics.
4 2 Create
4.2 C t d data
t
Value mask
Depending on the catalogue selection, both the reference values and the results
measured byy the appraiser
pp are documented.
43E
4.3 Evaluation
l ti
Fleiss´
Kappa
St ti ti
Statistic
without Q-DAS is adopted to
Standard
assess the consistency
and accuracy of
Fleiss´
classifications/
Kappa
St ti ti
Statistic decisions by examining
with the results within
Standard appraiser, between
appraisers
i andd against
i
the standard.
Fleiss´
Kappa
Summary
(sheet 3)
44R
4.4 Reportt
Select the Report menu (item) in

order to select a report
report. After
selection, the program searches
the printer
(printers must be available before
starting the Q-DAS software).
Only reports that have been saved

in the active program module are
displayed.
5 Key
5. K commands
d
qs-STAT V10 – Process capability analysis
 F1 - Help & user manual
 F2 - Value chart
 F3 - Value plot
 F4 - Histogram
 F5 - Probability plot
 F8 - Quality control chart
 F9 - Execute evaluation (from version: ME_7)
ME 7)
 F10 - Form sheet – design 3 (overview)
 F12 - Form sheet – design 4 (statistic evaluations)
 <ESC>
ESC - Closes
Cl graphics
hi
 <ALT><First letter> - Opens menu
 <STRG><TAB> - Switches between open p g graphics
p & form sheets
5 Key
5. K commands
d in
i masks
k
Values mask
 <STRG><C> - Copy to the clipboard
 <STRG><V> - Paste from the clipboard
 <STRG><G> - Selectl the
h ““Goto““ mask
k
 <STRG><M> - Open the characteristic mask
 <Insert> - Add "cells"
 <Delete> - Delete measured values
 <Pos 1> - Move to the first cell
 <End> - Move to the last cell
Characteristics mask
 <alt><V>
alt V - Paste characteristics with values
 <Paste> - Append a new characteristic
 <F11> - Configuration data acquisition (part level)
 <Shift key> - Configuration data acquisition (standard)
 <F12> - Open properties of the active characteristic
 <STRG><G> - Select the “Goto“ mask

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Verwandte Titel

Training

Capability of visual inspections

• Name Capability of visual

Statistical Procedures for Machine and Edgar Dietrich

Minitab Cook book Isaac Newton 978-1782170921 $50

Capability of visual inspections

QM-TQ017 Measurement uncertainty

QM-TQ061 qs-STAT/solara basic training

Knowledge exchange about visual inspections

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Capability of visual inspections

Time Subject Referee

12:15 p.m. – 01:00 p.m. = Lunch=

01:00 p.m. – 02:30 p.m. 1st Team work / discussion Participants

02:30 p.m. – 02:45 p.m. = Break =

02:45 p.m. – 04:00 p.m. 2nd Team work / discussion Participants

Capability of visual inspections Introduction 2 3 4 5

2 • Terms and definitions

7.6.1 Measurement system analysis

* Source: ISO/TS 16949: 2009(E)

Capability of visual inspections Introduction 2 3 4 5

16. Control of inspection,

* Source: VDA Vol

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Capability of visual inspections Introduction 2 3 4 5

Yes/no Number of failures Grades Cycle time of an order in

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• Characteristics are described by whole numbers only

• Data is assigned to ranked categories.

• Characteristic values exhibit a rank order

Categories • Elements are assigned to categories

Capability of visual inspections Introduction 2 3 4 5

diameter of a turning workpiece

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Measurement Gauge See Taste

Capability of visual inspections Introduction 2 3 4 5

Procedure 6 Bosch booklet 10 Procedure 2

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Capability of visual inspections 1 Preparation 3 4 5

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The last one was easy? So

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Capability of visual inspections 1 Preparation 3 4 5

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* Source: EN ISO 9712 - June 2012 - page 11

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