Original Date: 04/20/1998
Revision Date: 01/18/2007

In 1996, ITT Aerospace/Communications Division (A/CD) established the Operator Self Inspection (OSI) program to integrate the inspection step into the production process, verify instruction documentation by the end user, and strengthen build-to-print capabilities. By checking the product as it is being produced, operators can identify problem indicators early in the process, and minimize waste, redundancy, and rework. The OSI program is typically implemented into a pilot area of a production process, and run as a dual system against traditional inspections until the area is validated.

ITT A/CD maintains control of OSI through three procedural documents: OSI Certification/Audit System; OSI Procedure; and First Piece Inspection Procedure. These documents address various topics such as OSI definitions, operator certification, audits, procedural instructions, manufacturing verification, and record keeping. Operators must successfully pass audits of their work in production to become OSI certified, maintain this certification, and be re-certified if changes occur with the product or production process.

Operator ownership is the key to the OSI program. ITT A/CD’s OSI operators are well trained, think proactively, function independently, require minimal supervision, and accept the responsibility and authority needed to oversee a process. By using OSI, the company reduced its in-process inspection costs by 75%, decreased cycles times, developed a quicker response to rework, eliminated inspection queues, and established a flow-down checking with Quality Control Final Inspection.

For more information see the Point of Contact for this survey.