3. Prepare a detailed summary to supplement Hemant's possible recommendation and justification so as Tushar can understand how he arrived at those recommendations.

Krishna Electricals is a medium-sized manufacturing company of wire windings used in making electric motors. Tushar, Operations Manager, has been experiencing an extreme problem with rejected products found during the manufacturing operation. "How to find solution and where to start", said Tushar at the weekly staff meeting with his boss. "Rejects, scraps and reworks in the winding department have been wiping out our profits for the past two months. Nobody in operations has any clue, why it is happening. I have just discussed with a consultant, Hemant, to take a look at the situation and make recommendations about how we can find out the real cause of what is going on. I don't expect Hemant to make any technical recommendations. Let us just see if he can take us only to the right direction." Hemant first landed that day to the production shop-floor. His discussions with the production people, in- cluding supervisor in the winding department, indicated they had no real knowledge of what the problem and its cause was or how to rectify it. There were three machines that wound wire onto plastic cores to produce the primary and secondary electric motor windings. After inspection by quality control (QC), these windings were taken to the packaging department. Packaging personnel, Hemant found, inspect their own work and make corrections there itself. The problem was that too many windings were found to be defec- tive and required reworking before they could be packed.