Gage pin control

[Billmill]

Historically in the company I work for (about 100 employees on the floor), we've had a problem with keeping track of pins. Either they're not returned or are lost and this has become an action item for our Continuous Improvement Task Force. Every member of the panel has a differing opinion as to how to handle this cost-heavy conundrum (i.e. log out sheet, bar-coded gage kits, Robo-crib, etc. etc.) Has anybody out there had this problem and fixed it with any degree of sucess?

[CatMan]

We don't have a problem with this issue, but the way our company handles it is like this:

Each pin gets assigned a number. This number is etched onto the handle of the pin (not the pin itself). This gauge gets checked out to an individual. This is all tracked in a system we have called Gage-It. Anything would work though, sheet of paper, excel, etc. Our system creates an audit where all gauges have to be returned to the gauge lab and checked bi-monthly, semi-annually, etc. The system creates a list of all the gauges that should be in the area. If you don't have gage # 1234-BRX-002 0.500" pin gauge, then you have to fill out a lost gage form. This form requires the signature of your boss, your manger, quality supervisor, and quality manager (make this an unpleasant experience).

The form is kind of the meat of the matter. I don't know what you could threaten to with hold until the gauge is found, but think of something. No raises, no vacation, etc. The other key point of the system is the gauge audits. Make the operator find the gauge every month so he/she knows where it is and doesn't have to think back a year of where they put it.

Works for us, but like I said, I don't think we have a problem with this issue.

[Spinit]

We have problems with gage pins missing. The most important thing is actually having gage pins so if something is missing it must be found or replaced. We are using a board with markers and a eraser and we are supposed to sign out any company tool or gage pins used and this system helps. With gage pins I think we should buy or make pin holders because it is harder to lose or misplace them. We have nothing now in that department. Even some kind of box to hold the pins being used seems to help. I finally bought personal sets as of late and will not break them out until I get something to hold them together while I am using them. I like the ideas mentioned so far.

[PixMan]

There are some nice anodized aluminum pin holders (a.k.a. "pin vises") out there which hold both the "go" and "no-go" pins needed for any particular gauging setup. Too much money in some cases, so for the smaller (more easily lost) pins I had simply bought a good supply of Starrett #240 pin vises that handles the range of .010" to .200" pins.

They have some with octagonal plastic handles, and double-ended ones, but I just used Ebay to find the cheaper single-ended steel ones. Two complete sets plus a couple of spares, I don't think I spent more than $25 total. I haven't lost a small pin since I started using them.

[Clive603]

Tag, handle or whatever on the pin to make it harder to loose is good.
Can help to look at actual (not ISO or what ever theory manual) working practices.
With a little bit of thought and appropriate mods doing it right can be made to emerge easily from what is normally done. Trying to fight local practice by imposing rules, forms and procedures is a loosing battle. What's worse is it tends to upset the guys storing up trouble elsewhere. You gotta get the troops on the ground on your side "OK folks hunting around for gauge pins is wasting time costing you money and darn frustrating. Lets see what we can do to make life easier. How about ... which ought to work." not "You untidy, careless, thieving slobs keep loosing gauge pins. From now on you will .... [20 procedures omitted] .... and fill in ....[ 10 forms omitted] ..."

For example:-

What's the local culture as to holding / returning tools / gauges to stores? Immediately when finished with, end of day, end of week, when I think about it or when the moose bellows?
Do the job timing or shift timings actually allow time to return stuff to the stores in a timely manner?
Does it make sense to have enough pins etc to make up sets for regular jobs so the set can be issued with the job ticket and returned at wrap up?
Are there specific places for each user to keep drawn from stores gauges, instruments or whatever separate from their personal issue / supply?

and so on.

Clive

[tlipton]

With a shop that big you must be using some kind of traveler/scheduling system. The gages for the job should be kitted with any special cutting tools or fixtures and staged with the job. The job planners and schedulers actually probably write sentences like, "Verify tolerance of .500-.503 diameter hole with pin gage" These things are pretty cheap (class Z) in the scheme of things. Pin gages up to an inch cost less than many carbide inserts that are used up almost without thought. I bet they have all the cutting tools they need for the job right?

If your machines are set up in cells get a complete set for each cell. In some central toolroom (I'm guessing you have one) keep spares just like you keep your drills and taps. I would also venture a guess that a decent portion of the missing pins are common sizes, .250, .375, .500 etc

In our shop the rule was that if you needed a pin from the .061-.250 set you took the whole box. The big wood box is easier to spot when trying to track one of the rather smaller individuals down. We had a whiteboard signout near the shop pins so all could see who had the box. Its also harder to pop the whole box of pins in your toolbox when you are getting ready to cut out for the day. Paint the boxes blaze orange and make it one of the trainees jobs to inventory the pins on some interval.

If you do have a tool room It sounds like its "self service" The chit system has worked for as many years as the central tool room has existed. If the toolroom is self service its nobody's territory so there are no real consequences to not returning things. If there is a gruff old snarler holding on to a chit with your name on it or your car keys you bet you will bring that .251 pin back. The honor system only works in small shops you can yell across. You can bet if that machinist bought that pin set with his own money he will make sure its complete and gets back in his kit at the end of the day or he sure as heck knows who has it.

The only other thing worth mentioning is food. Put a bucket of roasted peanuts or a popcorn machine right where the pins are stored. I have not met a machinist yet that could resist free shop food. Bring the pin back get some peanuts. Simple human psychology.

Cheers.

Tom Lipton

[Billmill]

Thanks for all the good input. In any case it's going to take discipline to move forward on the floor's end and maybe a little money from senior mgmt.