Quote Originally Posted by Sephex View Post
I guess this is a complaining about your job thread now?

Being Quality Assurance at a facility that manufactures conveyors from scratch has been absolute hell for me. (SPOILER)Long story shot, the president (though he isn't the highest ranked boss) got mad because a specific unit was messing up in the field. It became absolutely clear that the problem stemmed from a design flaw that fell on the shoulders of the engineers. For whatever reason, the engineers can do no wrong in his eyes.

So he started screaming and pounding his desk (yes, there are bosses who actually do this in real life), turned a blind eye to the real issue, and said manufacturing was to blame. We now have to inspect certain parts for 100% inspection. Usually, we do a first piece check or a few checks per batch, which is normal procedure for just about any place that has a QA department. Now, we are expected to look at every single part per work order, tag each part with a sticker, and tie a hand written aluminum tag on each part as well. Then we have to log each recorded dimension on a spreadsheet (one for each part) that is stored on the server.

An order of 35 parts that aren't even that big will take two or three hours. We work 8 hours a day and aren't allowed overtime. If we were, even two or three hours of overtime wouldn't give us enough time. Orders are starting to back up already, and the president is already starting to complain that we aren't working fast enough. Oh, and some of these orders are for big parts that are over 100 pieces on the work order.


I'm in hell.
Your best hope is that when the parts continue to fail in the field even with 100% inspection and parameter verification he'll be forced to conclude it's not a QA/Manufacturing issue, but indeed a design flaw. You can check those parts all you want, but if the original design is flawed then basically all he's paying you to do right now is verify that every single one of them is a turd.

Hopefully this 100% inspection policy will result in him seeing the real issue here soon.