Are there any customizations someone has built to tackle the obstacle of choosing multiple reason codes? It is impossible for our floor operators to log into MES with the production process of reworking defects in our product. They crawl into very tight spaces and work on a group of defects, and it would not be efficient to have them crawl in and out to perform data entry in MES as the defects are worked on. It is not possible to create one reason code that will accurately describe multiple defects as the product can vary from 5 to over 150 defects.
Could you explain this a bit more? We use reason codes quite a bit.
Sure, we produce aircraft fuel bladders. We are wanting to implement Data Collection (MES), this is the only area of our company we haven’t due to its complexity. As the product moves into this area, there is a 100% chance a cell will have some form of defect. We treat this as a standard, and added it to the routing of the parts. Our plan is for the initial defect rework (or standard in this case), which varies by job, will be updated in job entry by an engineer after initial inspection. Employees will log labor against this initial set of defects via “Start Production”. The operators will mark this operation complete once the initial set of defects are suspected complete. Quality will then inspect the part, and find more defects or the initial ones were not complete as marked. We are wanting to then use the “Start Rework” button in Data Collection instead of “Start Production”. They must crawl in these fuel cells to work on the defects. You can only select one code in the Start Rework page. It would be inefficient to have them crawl in/out of the cell to log labor as they work, as I mentioned a cell could have up to 150 defects.
Let me also add that we are not using the quality module at all with these defects. Our goal is to minimize creating new operations/adjustments to the job as these defects are eliminated or reworked. We want to limit the adjustment to the operation on the initial check as it moves down the production line.