Containment/Quality
What is the first step when containing bad parts at the cell?
Stop the process!
When should you put your safety glasses on?
Before you enter the production floor
What check-sheets are you responsible for? There are 4
Operator Inspection, Quality Defect Alert Review, Weld Destruct Pick-up, Work center Set-up
What is the first thing you MUST do when new containers are brought to your station?
YOU MUST remove old labels
What are our 3 core values?
Safety, Ownership, Teamwork!
Where on Plex can you find your Containment instructions?
The Paperclip/Instructions
When should you not touch anything on the machine?
When it is LOTO
When your machine goes down and you check the HMI screen and it says "Fault, Tip Change" What should you put your status in?
"Planned Downtime Tip Change" and then turn your red light on!
What is the BEST way to verify that a label you just created is correct?
Match the part number on the label to the part number stamped on the part.
What is the quality policy?
Challenge Manufacturing is committed to customer satisfaction and continual improvement!
What are operators supposed to do every 15 minutes to prevent defective parts from getting packed into finished goods.?
Visual Checks
What activities can be done with the light curtain?
Only placing a part ON and OFF the fixture.
At the end of the day, what do we change our status to and how to do we log out of the work center?
Change status to 90 Off, and clock out of building!
How do you verify that you have the right container/packaging?
Go to the Packaging Instructions
Which Challenge plant was the very first Challenge plant?
A. Irving, Texas
B. Kansas City, Missouri
C. Spartanburg, South Carolina
D. Walker, Michigan
D. Walker, Michigan
We just got a new quality alert for a winking nut. If you are placed at this station and you are not sure what corrective action has been put in place.
What should you be checking daily on plex?
Quality Defect Alert Review Check-Sheet
When you are using bone conduction headphones at the work station and your team leader asks you to move to another station you should?
A. Log out of plex and move
B. Log out of plex, take your headphones off and move
C. Move stations
D. Change your status to 90 off, log out of plex, take your headphones off, then move stations.
D. Change your status to 90 off, log out of plex, take your headphones off, then move stations
Bone conduction headphones should only be worn at the station, and should never be worn when walking around the production floor.
When there is a check-sheet in plex that you can NOT do like Weld Destruct or First Piece what status do you put in?
Planned Downtime Plex Check-sheets
You go to print a label and notice you don't have enough inventory to print a label. At your station you have a full container of parts that you are still working with and the serial number has been loaded already into your plex. The inventory is stating ZERO, but you have parts... What should you do?
Tell your team leader/supervisor
We want to make sure our inventory is correct, and in order to do that we need to escalate to our team leaders and supervisors so the container can be taken away.
How many Challenge plants are there currently?
A. 7
B. 14
C. 12
D. 9
C. 12
Name 5 Defects.
Porosity, Weld Spatter, Burn-Through, Off Location Weld, Winking Nuts, Loose Studs, Cracked Nuts, Cold Welds, Expulsion, Off Location stamping/welds, Missing Welds, Bad Cut-Off, Burrs, Slug Marks, Bent Parts, Mis-formed Parts, Split, Fracture.
When it comes to forklifts name 3 safety incidents that you should report to your Team Leader.
Near Miss, Seatbelts, Headphone usage/Phone, Not stopping at stop signs or intersections, If they're driving too fast, too many containers, not driving backwards with containers, not using horn, driving in the pedestrian isle. Driving too close to team members
Let's say you're running a hot machine for the day, and your team leader says the machine has to keep running through break. When it's time for your break what would you put your status in?
Leave it in production
What are the consequences if we do not hit rate consistently?
Working weekends, Damages ESOP, Loss of contracts, develop a bad reputation.
When was Challenge founded?
A. 1983
B. 1979
C. 1982
D. 1981
D. 1981