FURTHER THOUGHTS

1
FURTHER THOUGHTS

• SHARE RESULTS WITH EMPLOYEES.
• MANAGEMENT REVIEW WITH EMPLOYEES IS ESSENTIAL TO
  SUCCESS.
• PROCESS SHOULD BE CONTINUAL. IF IT IS
  INTERMITENT, EMPLOYEES WILL SENSE LACK OF
  MANAGEMENT COMMITMENT.

2
CORRELATION OF DATA

• BIN ACCURACY HIGHER THAN INCOMING.
• PICK ACCURACY HIGHER THAN BIN ACCURACY.
• PACK ACCURACY HIGHER THAN PICK ACCURACY.
• OUTGOING QUALITY LEVEL BETWEEN AVERAGE OPERATIONS
  LEVEL AND CUMULATIVE OPERATIONS LEVEL.

3
BIN ACCURACY HIGHER THAN INCOMING

• BIN ACCURACY SHOULD SHOW HIGHER LEVELS THAN
  INCOMING.
• IF LOWER, PUT-AWAY STOCK OR PICKING IS MIXING
  STOCK.
• GOOD LEVEL OF STOCK ACCURACY IS 99.3 CORRECT.
  LOWER THANTHIS MEANS ADDED COST AND/OR POOR ORDER
  ACCURACY.

4
PICK ACCURACY HIGHER THAN BIN ACCURACY

• PICK ACCURACY SHOULD BE HIGHER THAN BIN ACCURACY.
• IF IT IS LOWER, PICKING MAY NOT BE COUNTING, OR
  PICKING FROM WRONG BIN.
• MINIMUM LEVEL OF PICKING ACCURACY IS 99.7 .
• LOWER LEVELS MEAN POOR CUSTOMER SATISFACITION.

5
PACK ACCURACY HIGHER THAN PICKING

• PACK ACCURACY SHOULD BE HIGHER THAN PICKING.
• IF LOWER, GOOD CHANCE PACKING IS NOT COUNTING.
• MINIMUM LEVEL OF PACK ACCURACY IS 99.8.
• LOWER LEVELS MEAN POOR CUSTOMER SERVICE.

6
OUTGOING LEVEL BETWEEN AVERAGE AND CUMULATIVE
OPERATIONS LEVEL.

• CANNOT BE LOWER THAN AVERAGE LEVEL OF ACCURACY
• CANNOT BE HIGHER THAN CUMULATIVE LEVEL.
• IF SO, AUDIT MAY NOT BE STATISTICALLY SOUND.

7
LOT ACCEPTANCEAddl.

• GET COPY OF MIL STD 105E FROM THE GOVERNMENT
  PRINTING OFFICE.
• SELECT THE APPROPRIATE AQL LEVELCGA USES 2.5.
• USE SINGLE SAMPLING PLANS, LEVEL II INSPECTION
  FOR APPAREL.
• BEGIN WITH THE NORMAL SAMPLING PLAN.

8
LOT ACCEPTANCEAddl.

• MAINTAIN NORMAL LEVELS FOR BEST RESULTS.
• GO TO TIGHTENED SAMPLING PLAN WHEN 2 OF 5
  CONSECUTIVE LOTS FAIL (IGNORE RESUBMITTED LOTS).
• GO BACK TO NORMAL WHEN 5 CONSECUTIVE LOTS PASS.

9
LOT ACCEPTANCEAddl.

• GOING FROM NORMAL TO REDUCED
• 10 CONSECUTIVE LOTS HAVE PASSED.
• PERCENT DEFECTIVE IS EQUAL TO OR LESS THAN THE
  AQL LEVEL USED.
• PRODUCT IS CONSISTENTNOT A NEW STYLE OR
  SUPPLIER.
• RESPONSIBLE MANAGEMENT DEEMS THIS NECESSARY.

10
LOT ACCEPTANCEAddl.

• GO FROM REDUCED TO NORMAL
• IF A LOT IS REJECTED.
• IF DEFECT LEVEL IS BETWEEN ACCEPTANCE AND
  REJECTION LEVELS.
• SUPPLY OF PRODUCT IS INTERRUPTED OR IS A NEW
  PRODUCT.
• INTERNAL PROCESS IS CHANGED OR INTERRUPTED.
• MANAGEMENT DEEMS IT NECESSARY.

11
USE 105E TABLE TO SET LEVELS OF SAMPLING

• CONSIDER THE NUMBER OF UNITS OF WORK PROCESSED AS
  THE LOT SIZE.
• THE NUMBER OF UNITS TO SAMPLE CAN BE OBTAINED
  FROM THE SAMPLING TABLE. CONVERT FROM GARMENTS TO
  ORDERS, BINS, ETC.
• THIS METHOD CAN BE APPLIED TO OPERATIONS AUDITING
  OR SKIP SAMPLING.

12
A USEFUL TOOLTHE AQL INSPECTORS RULE

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