Improvement of post-treatment inspection processes

In the production process of rubber products, the post-treatment inspection process is a key link to ensure product quality. However, the inspection process itself does not directly create value, but indirectly supports the smooth progress of production through strict quality control. At the same time, due to the repetitive and labor-intensive characteristics of the inspection process, there is a large turnover of personnel, which also brings many problems to production and quality control. In order to deal with these problems and comprehensively improve the efficiency and quality of the post-processing inspection process, we have made improvements in the following aspects:

1 Personnel ability training, assessment and landing

Manual inspection is susceptible to fatigue and other factors, resulting in slow inspection speed, but also difficult to avoid human error, especially after a long time of work, the operator's concentration is reduced, which is the most important reason for missing defects. In view of the above problems, we are implementing the following methods in personnel training:

1.1 Equipment and process training: Conduct comprehensive training on equipment operation and process flow to ensure that operators are familiar with the use of equipment and standard process flow.

1.2 Product requirements training: Training on the special requirements of different products to ensure that operators understand and master the specific inspection standards and precautions of products.

1.3 Training records: For each training, the training content, the list of participants and the training effect evaluation are recorded in detail to ensure the effectiveness and traceability of the training.

1.4 Assessment mechanism: Conduct regular skill assessment to ensure that each operator can reach the required skill level.

1.5 Ability Matrix diagram: The ability matrix diagram shall be established to record the skill level and training progress of each employee, so as to facilitate the reasonable arrangement of work tasks and the continuous improvement of employees' abilities

1.6 Continuous supervision: Through long-term on-site supervision and feedback mechanism, to ensure that each operator can correctly apply the relevant knowledge in actual work.

2. Use of automation

In addition to visual inspection, Masamura is also committed to the implementation of automated inspection, and an existing optical inspection equipment has begun initial use.

2.1 The optical inspection equipment is positioned by CCD and uses a high-resolution camera to shoot the product in an all-round way, automatically identifying and marking surface defects to ensure accuracy and consistency in the inspection process.

2.2 Due to the limitations of the equipment, at present, through product debugging, the existing production of O-rings and other rubber products can be used in batches.

2.3 Implementation effect: reduce the uncertainty and fatigue of human inspection through automatic inspection import. The application of optical detector has increased the inspection efficiency of some existing O-rings by 80%, greatly optimizing the entire production process.

3 Check exceptions and turnover management

When the operator finds an abnormal situation in the daily inspection, he will immediately contact the team leader through the paging system, and the team leader will make a preliminary judgment after confirmation and report the problem to the abnormal group within the company.

3.1 Abnormal problems will be broadcast in the corresponding wechat group, and the relevant person in charge will confirm, analyze and improve the group. After the problem is solved, the relevant person in charge will confirm and close the exception report in the group to ensure that the problem is effectively solved.

3.2 Turnover Management

All products implement the management system of "one material, one box and one label". The materials in each box are uniquely identified to ensure traceability and transparency of management.

4. Use of visualization

A tablet is installed on each inspection table to broadcast the inspection steps in real time, ensuring that the operator is strictly following the standard process requirements.

4.1 Standardized operation: Ensure that each step of the operation has clear guidance to reduce the deviation of human operation.

4.2 Training assistance: Instructional videos and graphic instructions on tablet computers can be used for new employee training to improve the training effect.

5 Check the area improvement plan

The existing inspection area has a large noise interference, which affects the operator's concentration and efficiency.

5.1 Reduce interference: Minimize noise through layout changes, improve operator concentration, and reduce inspection errors caused by environmental interference.

5.2 Environmental improvement schema: Draw an environmental improvement schema to clarify specific plans for various improvement measures to ensure that environmental conditions meet production requirements.

In the future, we will continue to explore more innovative ways to continuously improve the production efficiency and quality level of rubber products, and provide customers with better products and services. With the continuous introduction of automation equipment and technology, we are confident of achieving greater breakthroughs and developments in the next few years.