Cylinder Boring Case Study

Normally, the large automakers demand 0 defects from their suppliers. However, it is challenging for Metalcraft to achieve extremely low defect rate and succeed among rivals. Therefore, to solve the problem of control during the supply chain

A process that monitors standards by take measurements and corrective action as needed. It is in control when only variation is natural, if variation is assignable then discover cause eliminate it. Take samples to inspect/ measure- reduce inspection time, reduce opportunity of bad quality. Control charts graph of process data over time-show natural and assignable causes. Control charts for variable data (characteristic that is measured, length,height, etc) are X-chart (average) and R-chart (range)must use x and r to get correct results. central limit theorem follow normal curve. When we know . When we don’t know . Control charts for attributes (categorical-defective, good/bad) P-chart (percent) or C-chart

This type of chart is used when one wants to identify the total number of defects that have occurred during a sampling period. The number of samples that occur during the period are essentially the same. This chart has the number of defects on the vertical axis and the number of samples (weeks) on the horizontal axis. The sample size for this problem is over a period of 20 weeks, where a new process was implemented at week 11. Since a new plan was implemented, it caused the two different graphs to appear. The first graph, which occurs before week 11, has a UCL of 28.4 and an average of 16.3. A UCL stands for an upper control limit, which is generally 3 standard errors from the median, and is always the top line of the graph. The median is used as the centerline of the graph. An LCL is apparent in the graph (bottom line), but no exact value is given. The points that are shown on the graph are the “statistical measurement samples taken from the process at different times” (Control Charts PPT., 25, 2016). The second graph, which occurs after week 11, has a UCL of 7.4 and an average of 2.6. This subgroup is also complete with an upper UCL line and a median centerline. After week 11, a new plan was implemented into the hospital to reduce the number of defects. The plan that they used decreased the total number of defects, decreased the UCL, average, and LCL. A strategy that may have been able to reduce the amount of defects was Six Sigma. Six Sigma would work for this type of scenario because it measures how many defects exist in a process and you can figure out how to eliminate them all

The automotive component & Fabrication Plant, ACF, was the original plant site for Bridgeton Industries, a major supplier of components for the domestic automotive industry. All of the ACF’s production was sold to the Big-Three domestic automobile manufactures. Its main competitors were local suppliers and other Bridgeton plants. This company did very well but recently it became less effective when foreign competition and scarce, expensive gasoline caused domestic loss of market share. For boost its selling, it made four criteria, quality, customer service, technical capability, and competitive cost position to evaluate three classifications of products.

Situation analysis: CMI is looking to diversify its portfolio. It wants to introduce a new high performing cushion pad into the pile-driving market. CMI will initially target small engineering/construction and independent pile-driving contractors. CMI will have the first-to-market advantage, as there are currently no direct competitors for metal pads. In terms of channels, CMI would distribute its pads through manufacturing representative.

This week’s assignment is about evaluating the quality issues of three organizations. The three sectors I chose to evaluate are manufacturing, service and government. I will then discuss the importance of quality to each organization, the relationship of quality to customers, the leadership commitment to quality and the alignment of quality to the organization’s strategic goals and objectives.

Mr. Aly Tapily is working as a Material Data Analyst. Under the supervision of the MPR Control Manager he is tasked to provide manager services per assigned work by Industrial Engineering Manager and Supply Chain Manager. Aly’s primary function in this position is to analyze and monitor the quality of data from Engineering and Industrial documents during product manufacturing by analyzing data collected to find discrepancies. To successfully complete this task, he needs to have an ability to read and understand engineering drawings/schematics, a good understanding of electrical and mechanical components needing in production, and good statistical analysis skills. Aly is also responsible for extracting required data from the company’s database and ERP system or other systems used for Bill of Materials (BOM) and procurement. He then has to report findings in clear concise format to project managers for resolution. These duties among others, while working on the different projects, will help Aly’s knowledge of different engineering procedures taking during product manufacturing, process analysis and control, project management, database technology, data reporting skills, and statistical skills learned through his engineering degree.

Curled Metal Inc. (CMI) specializes in selling metal-based products to various markets. With over $55 million in annual sales (FY 2007, Exhibit A), they’ve managed to capture 80% of the automobile industry’s market share by developing and selling a highly specialized product, Slip Seal, designed just for auto manufacturers. They’ve seen a recent slip in sales (a loss of nearly 10% from 2006 to 2007, Exhibit 2), and the pressure is on them to diversify their product line and decrease dependence on the auto industry. They’ve recently developed a new product that aims to revolutionize the pile-driving industry. The introduction of the CMI Cushion

Identify a business that has recently launched a quality improvement initiative (Harley Davidson would be just one of many examples). Your business could be one that is primarily product-providing or one that is primarily service-providing. Do some independent research in order to provide an overview of this initiative and the results of their efforts. The overview should take the form of a two-page paper. Within that assignment, cite examples of any control costs or failure costs that you can identify, in addition to prevention costs, appraisal costs, internal failure costs, and external failure costs (all of these terms are defined in considerable detail in section 8.8 of your textbook).

Also MAN (Materials –As – Needed) program was expected to improve the quality because lower inventory levels would make quality problems more apparent and force employees to take faster action

Yasin and Alavi (1999) conducted a quantitative study to determine if Total Quality Management (TQM) can produce quality improvement

The first process examined uses the Lablond Lathe machinery and requires a machined diameter of 7.7250, plus tight tolerances of + .0005 inches. A Process Capability Ratio (Cpk) analysis of the lathe’s data, results in a Cpk of .379 (exhibit A). A result of less than one indicates the machine is not capable of matching the tolerances laid out in the IMS spec. Therefore the Lablond Lathe is not suitable to handle the process it is being used for. Before a more suitable machine is selected, the Lablond Lathe should be checked for calibration, as should the measuring equipment used. If all fall within calibration specs, new

After Natalie’s further investigation, it turns out that the reason for the particularly bad results of work on Day 17 is the low temperature in the morning on which the batch was produced. By installing a thermostat in the manufacturing hall they solve this problem. Now, what Natalie should do next is to take this special batch out of the data and draw another Xbar-R chart. After excluding this special case from the data, Natalie can evaluate the rest of the data independently from this “special event”. The new Xbar-R chart shows this one special batch is not the reason why cam rollers always fall short. From the new chart, Natalie might identify what

Continued quality issues with our DGS, a critical part within LongXi’s Small Multi-Cylinder Diesel Engine has resulted in breakdown, engine failure and loss production at several customers. Customer complaints are increasing and we need to react to and eliminate our quality concerns. We must develop ways to improve quality in house. Our QC group is well established therefore we are recommending that we collect and analyze data relative to why the DGS is failing and

The ADI’s strategy in 1986 is based on Quality Improvements and Manufacturing Cost Reduction. The Quality specialist of ADI, Schneiderman believed that if the efficient