Check the same four places as the first time: at the customer, in transit, in finished goods and in work in process. Write down what each holds, including a zero. Sort every piece with a gage that reads the characteristic, because the old first piece check passes while the defect is being made. Name the first clean lot and put it on the report and the label.
Tuesday afternoon, finished goods. Two lots are packed and waiting for a truck. Nobody has checked them for hole spacing, because nobody checks hole spacing at packing. It is back, so everything made on die D-3082 since the last good check is suspect until you have looked at it.
The same four places apply as the first time, with less patience from the customer. Do them in order and write down what each holds.
- At the customer. Ask how many pieces they have, and whether they will sort or send back. Here the customer sorted lot 6471 and found 7 bad of 120.
- In transit. Nothing was on a truck this time. Write 0, because a blank looks like you forgot.
- In finished goods. 240 pieces in two lots. Sort every piece on hole spacing with a fixture gage. Found 14 bad.
- In work in process. 310 pieces on the floor and in the die. Stop the press, sort what is made, and tag what is left. Found 18 bad.
The total sorted is 670 pieces. The total bad is 39. Those two numbers go on the report and they do not change unless someone sorts more.
Do not trust the old check
The first piece check is the one the old 8D leaned on. In this case it passed on every run, including the run that made the bad lot. A check that passes while the defect is being made cannot be your containment. Sort with a gage that reads the characteristic, and sort 100 percent.
Mark the first clean lot
Containment ends at a point you can name. Here it is the first lot built after the die gets a corrected setup, which becomes lot 6475. Put that lot number on the report and on the packing label, so the customer can tell which pieces to trust. Until it exists, everything before it is held or sorted.
Tell the customer what you found and what you will do before they have to ask twice. The report should not be the first they hear of the numbers.
Read more: containment vs correction vs corrective action, the red tag guide and the free containment checklist builder. Book 1 has the full walk through in Contain It.
The mistake to avoid
Containing only what the customer reported. They found one lot. You found 32 more bad pieces that never left the building, and the next complaint would have been the next lot.
- Look at what your last containment checked.
- Check all four places have a number, even 0.
- Name the first clean lot before you need it.
Open the printable Monday Board
Related on ShopFloorOps
The part, the die, the lots and every number in this book (sensor bracket BK-6139) are a made-up example. The tool sidebars show ShopFloorOps tools, which I make and sell. Every chapter teaches the step itself, so you can use your own forms. New to a term? See the quality glossary.