Skip to main content
SpringerLink
Log in

Evaluating and Improving the Effectiveness of Visual Inspection of Products from the Automotive Industry

  • Conference paper
  • First Online:
Advances in Manufacturing II (MANUFACTURING 2019)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Included in the following conference series:

Abstract

The article presents the results in the field of assessment and improvement of the effectiveness of visual inspection of products - airbag modules, manufactured by a company from the automotive industry (Tier 1 supplier). The research was carried out using the Kappa index and auxiliary indicators proposed by the automotive industry for the assessment of the inspection system consisting of 3 controllers involved in the inspection of the above-mentioned products. The results showed numerous interesting interdependencies in the inspectors’ classifying the specially selected sample of products into two qualitative categories (OK, NOK). The findings included, among other things, poor or average compliance of the controllers’ decisions with the expert’s decision, an unacceptably high share of the type II errors consisting in the acceptance of a non-conforming product - this applied to all controllers, and a poor result of the entire control system (3 controllers verified in total). Furthermore, the conducted research allowed to develop a ranking of controllers. The obtained research output led to actions intended to improve the alternative product control system including the trainings for all controllers, the modification of the visual assessment standard and implementation of the Andon system.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 84.99
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 109.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  1. Hamrol, A.: Strategies and practices of efficient operation. Lean Six Sigma and other (in Polish), (PWN), Warsaw (2015)

    Google Scholar 

  2. Czerska, J.: Improving the value stream (in Polish), (Difin), Warsaw (2009)

    Google Scholar 

  3. Borkowski, S., Knop, K.: Challenges faced in modern quality inspection. Manag. Prod. Eng. Rev. 7(3), 11–22 (2016)

    Google Scholar 

  4. Webber, L., Wallace, M.: Quality Control for Dummies. Wiley, Hoboken (2007)

    Google Scholar 

  5. Ulewicz, R.: Practical application of quality tools in the cast iron foundry. Manuf. Technol. 14(1), 104–111 (2014)

    MathSciNet  Google Scholar 

  6. Czyżewski, B.: Internal quality control in a production company (in Polish), (Wielkopolski Quality Club FSNT NOT), Poznan (2007)

    Google Scholar 

  7. Rewilak, J.: Do you trust visual inspection? (in Polish), TQM Soft. http://szkolenia.tqmsoftcom/inspekcja. Accessed 20 Mar 2013

  8. Kujawińska, A., Vogt, K.: Human factors in visual quality control. Manag. Prod. Eng. Rev. 6(2), 25–31 (2015)

    Google Scholar 

  9. Schultz, D.: Psychology and the challenges of today’s work (in Polish), (PWN), Warsaw (2012)

    Google Scholar 

  10. See, J.E.: Visual inspection reliability for precision manufactured parts. Hum. Factors 57(8), 1427–1442 (2015)

    Article  Google Scholar 

  11. Charles, R., Fletcher, S.R., Tailor, M.: Search patterns in human visual inspection. In: Contemporary Ergonomics and Human Factors, Proceedings of the International Conference on Ergonomics & Human Factors, 13–16 April 2015

    Google Scholar 

  12. Johnson, L.: Can You Improve Your Visual Inspection Process? https://www.minitab.com/uploadedFiles/Content/News/Published_Articles/inspection_process_improvement_breakthrough.pdf. Accessed 05 Dec 2018

  13. Hamrol, A., Kowalik, D., Kujawińska, A.: Impact of selected work condition factors on quality of manual assembly process. Hum. Factors Ergon. Manuf. Serv. Ind. 21(2), 156–163 (2011)

    Article  Google Scholar 

  14. Vogt, K., Kujawińska, A.: Analysis of the effect of the type of nonconformity on the effectiveness of visual inspection (in Polish). In: Knosala, R. (ed.) Innovation in Management and Production Engineering, vol. 2, pp. 470–480 (2014)

    Google Scholar 

  15. Kujawinska, A., Vogt, K., Diering, M., Rogalewicz, M., Waigaonkar, S.D.: Organization of visual inspection and its impact on the effectiveness of inspection, In: Hamrol, A., Ciszak, O., Legutko, S., Jurczyk, M. (eds.) Advances in Manufacturing. LNME, pp. 899–909 (2018)

    Google Scholar 

  16. Purswell, J.L., Hoag, L.L.: Strategies for improving visual inspection performance. In: Proceedings of the Human Factors and Ergonomics Society Annual Meeting, vol. 18, no. 4, pp. 397–403 (1974)

    Article  Google Scholar 

  17. See, J.E., Drury, C.G., Speed, A., Williams, A., Khalandi, N.: The role of visual inspection in the 21st century. In: Proceedings of the Human Factors and Ergonomics Society, pp. 262–266 (2017)

    Article  Google Scholar 

  18. Schoonahd, J.W., Gould, J.D., Miller, L.A.: Studies of visual inspection. Ergonomics 16(1973–4), 365–379 (2007)

    Google Scholar 

  19. Kavuri, S.H.: Size Effects in human visual inspection for micro/meso scale parts, mechanical (and materials) engineering. Dissertations, Theses, and Student Research, p. 81 (2015)

    Google Scholar 

  20. Thapa, V.B., Gramopadhye, A.K., Melloy, B., Grimes, L.: Evaluation of different training strategies to improve decision making performance in inspection. Int. J. Hum. Factors Manuf. 6(3), 243–261 (1996)

    Article  Google Scholar 

  21. Lee, J., Ko, K.W., Lee, S.: Visual inspection system of the defect of collets for wafer handling process. Int. J. Control Autom. 9, 129–138 (2016)

    Google Scholar 

  22. Drury, C.G., Watson, J.: Good practices in visual inspection, Human factors in aviation maintenance-phase nine, progress report, FAA/Human Factors in Aviation Maintenance (2002). https://www.faa.gov/data_research/research/med_humanfacs/oamtechreports/1990s/media/AM91-16.pdf. Accessed 29 Oct 2018

  23. Knop, K., Ingaldi, M., Śmiłek-Starczynowska, M.: Reduction of errors of the conformity Assessment during the visual inspection of electrical devices. In: Advances in Manufacturing, LNME, pp. 857–867. Springer, Heidelberg (2018)

    Google Scholar 

  24. Reinfus, R.: MBO - a simple and effective technique for managing your company (in Polish). Warsaw (2011). (Helion)

    Google Scholar 

  25. Knop, K., Borkowski, S.: The estimation of alternative control efficiency with the use of the Cohen’s Kappa coefficient. Manag. Prod. Eng. Rev. 2(3), 19–27 (2011)

    Google Scholar 

  26. Measurement System Analysis (MSA), Reference Manual, 4th Edn. AIAG Group (2010)

    Google Scholar 

  27. Diering, M., Kujawińska, A.: MSA-Measurement System Analysis. Guide to procedures (in Polish), Poznan (2012). (AR Comprint)

    Google Scholar 

  28. Gramopadhye, A.K., Drury, C.G., Sharit, J.: Feedback strategies for visual search in airframe structural inspection. Int. J. Ind. Ergon. 19(5), 333–344 (1997)

    Article  Google Scholar 

  29. Boucher-Genesse, A.: The Human Brain VS the Digital Brain - A Case for Visual Inspections (2016). https://blog.robotiq.com/human-brain-vs-digital-brain-what-is-so-different-case-study-for-a-visual-inspection. Accessed 30 Nov 2018

  30. Smith, C.J., Adendorff, K.: Advantages and limitations of an automated visual inspection system. South Afr. J. Ind. Eng. 5(1), 27–36 (1991)

    Google Scholar 

  31. Stoller, J.: The Lean CEO: Leading the Way to World-Class Excellence: Leading the Way to World-Class Excellence. McGraw-Hill Education, New York (2015)

    Google Scholar 

  32. Bożek, M., Rogalewicz, M.: The ineffectiveness of the final control the reason of the low efficiency of the production process (in Polish), Engineering of Machines (in Polish), R. 18, z. 1, pp. 84–96 (2013)

    Google Scholar 

  33. See, J.E.: Visual inspection: a review of the literature (Report SAND2012-8590). Sandia National Laboratories, Albuquerque (2012)

    Google Scholar 

  34. Clemons, A.J.: Training methods for visual inspection tasks. Iowa State University Capstones, Graduate Theses and Dissertations, 13005 (2013)

    Google Scholar 

  35. Ulewicz, R.: Outsourcing quality control in the automotive industry. In: MATEC Web of Conference, vol. 183, p. 03001 (2018)

    Article  Google Scholar 

  36. Klaput, P., Vykydal, D.: Effect of the number of non-conforming samples on the Kappa indicator values. In: MATEC Web of Conference, vol. 183, p. 03014 (2018)

    Article  Google Scholar 

  37. Diering, M., Dyczkowski, K., Hamrol, A.: Estimating the level of conformity of assessments in visual inspection - problems in determining the Kappa coefficients (in Polish), Innovations in management and production engineering (in Polish), pp. 257–268. Publishing House of the Polish Society for Production Management (2015)

    Google Scholar 

  38. Jarosz-Nowak, J.: Models of assessing the extent of agreement between raters using kappa coefficients (in Polish). Appl. Math. (in Polish) 8, 126–154 (2007)

    MathSciNet  Google Scholar 

  39. Wongpakaran, N., Wongpakaran, T., Wedding, D., Gwet, K.L.: A comparison of Cohen’s Kappa and Gwet’s AC1 when calculating inter-rater reliability coefficients: a study conducted with personality disorder samples. BMC Med. Res. Methodol. 13(1), 61 (2013)

    Article  Google Scholar 

  40. Starzyńska, B., Szajkowska, K., Diering, M., Rocha, A., Reis, L.P.: A study of raters agreement in quality inspection with the participation of hearing disabled employees. Advances in Manufacturing. LNME, pp. 881–888. Springer, Heidelberg (2018)

    Google Scholar 

  41. Anttila, J., Jussila, K.: Organizational learning in developing the integrated quality management. Prod. Eng. Arch. 18, 3–13 (2018)

    Article  Google Scholar 

  42. Grabowska, M., Takala, J.: Assessment of quality management system maturity. In: Advances in Manufacturing. LNME, pp. 889–898. Springer, Heidelberg (2018)

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Production Engineering and Safety, Faculty of Management, Czestochowa University of Technology, Armii Krajowej 19B, 42-200, Czestochowa, Poland

    Krzysztof Knop & Robert Ulewicz

  2. Faculty of Management, Czestochowa University of Technology, Czestochowa, Poland

    Ewa Olejarz

Authors
  1. Krzysztof Knop
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ewa Olejarz
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Robert Ulewicz
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Krzysztof Knop .

Editor information

Editors and Affiliations

  1. Poznan University of Technology, Poznan, Poland

    Adam Hamrol

  2. Poznan University of Technology, Poznan, Poland

    Marta Grabowska

  3. University of Maribor, Kranj, Slovenia

    Damjan Maletic

  4. Brandenburg University of Technology, Cottbus, Brandenburg, Germany

    Ralf Woll

Rights and permissions

Reprints and permissions

Copyright information

© 2019 Springer Nature Switzerland AG

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Knop, K., Olejarz, E., Ulewicz, R. (2019). Evaluating and Improving the Effectiveness of Visual Inspection of Products from the Automotive Industry. In: Hamrol, A., Grabowska, M., Maletic, D., Woll, R. (eds) Advances in Manufacturing II. MANUFACTURING 2019. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-17269-5_17

Download citation

  • DOI: https://doi.org/10.1007/978-3-030-17269-5_17

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-030-17268-8

  • Online ISBN: 978-3-030-17269-5

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation