Congratulations! You've just been hired by a company as their new Quality Manager. They are a large manufacturer of parts for the aerospace industry. The boss sits you down on the first day and indicates that "quality seems to be all over the place." He asks you to analyze the various parts of the process and provide some details and recommendations. He says: "You've got your job cut out for you...good luck!" He gives you the following data for # of bad parts produced per day for the last month and the bad parts produced per machine in the last month: Day 1 2 3 4 5 6 7 8 9 10 Defects 17 15 29 20 22 18 22 19 16 23 Day 11 12 13 14 15 67890 16 17 18 19 20 Defects 28 15 26 14 22 18 22 14 16 22 Day 1234333333 22 25 26 27 28 29 30 Defects 72167232024 16 22 19 Machine Defects per month 1 30 2 3 4 5 103 136 250 85 As a newly trained Quality Assurance Manager, you know that proper data analysis will be the first step. You go visit Ray, the Production Supervisor, for an overview of the process. He says: "Well, we get the raw material from our suppliers. As it comes in, we do an inspection and if product is good, it goes to the inventory area. However, if it's bad it goes into our quarantine area to go back to the supplier. We get an order to make new parts, so we will pull the stock from inventory to one of our 5 machines. The lead operator sets up the machine and then needs to get authorization the setup is ok. If it's ok, then we will run the order. If it's not, they redo it again until it is. Once the order is running, they will inspect 1 in every 10 pieces. They assess this sample to make sure its ok to keep running. If the inspection is bad, they go back to working on the setup. Once the order is done, it's sent to shipping. They wrap the order and send it to the customer. Pretty easy, really." You also find out they hired a consultant before you but she left before she was able to properly analyze the data and determine Upper and Lower control limits. However, the company, based on feedback from their customers, wants to see a goal of zero defects to a maximum of 10 per day. As you continue your investigation, you find out there has been a brainstorming session before you arrived so they could try to understand the recent quality issues. They put together the ideas in the minutes but haven't done any other analysis with them so far. They are: 1. Our raw stock over the last few months seems to be getting worse 2. We got a lot of new operators over the last few months who've been pushed to the floor quickly 3. The dial on Machine No 4 is worn out and very hard to read 4. We've been using the same specifications since I started here 10 years ago 5. I really don't know how they expect us to check the samples when half the lights are burnt out above the machine...I can't see anything! 6. I don't know what the issue is - I follow the standard procedures, same as John on Machine 1. Not my fault the other guys do things their own way. 7. I don't know how they expect the glue to hold when it's so cold in the warehouse 8. Machine No 3 has some very old parts that are loose 9. Bill is the only one who seems to know how to do the proper checks and he's off on sick leave 10. I'm told to do a different type of quality check by the designers, the supervisor and even the boss! 11. When setting up our dies, the wood used on the dies is brittle and can crack causing issues 12. I've tried to check the depth of the finished goods, but the tape measures are all different Digging further, you determine that the organization has set up an AQL for their inspections as per below: Major Issue - AQL of 0.1- with a lot size of 25,000 pieces and using General Level 2 Medium Issue - AQL of 0.65- with a lot size of 25,000 pieces and using General Level 2 Minor Issue - AQL of 6.5 - with a lot size of 25,000 pieces and using General Level 2 Finally you are given the following quality costs for the last year: Qualifications of Supplier Products Laboratory Support Process Control measurements Field Performance Evaluation $575 Depreciation Allowance Review of Test and Inspection Data Measurement Equipment Inspection and Test Materials Purchasing Appraisal Costs Maintenance & Calibration labor Retrofit Costs Warranty Claims Recall Costs Disposition Costs Troubleshooting costs Scrap Costs $585 $675 $2555 $2354 $265 $554 $360 $39,890 $28,000 $250 $1960 $155 $4558 $22,000 $225 $38,675 $1,200 Material Review and CAR Costs Supplier Reviews Operator Quality Education Contract Review Quality Administration Now that you have everything, it's time to get to work! $4,560 $50 $550 For this assignment, you must do the following: Analyze the quality costs, separate each one into each cost type and determine % in each cost type. Do not round up or down - show to two decimal points (i.e.: 00.00%). Create an Ishikawa Diagram of the brainstorm session Create a detailed flowchart of the process Create a control chart of the appropriate data - show your calculations and do not round up or down - show to two decimal points (i.e.: 00.00). Create a pareto chart of the appropriate data Calculate what the AQL information is Finally, on minimum two full pages to maximum three full pages (font size 12, single spaced), provide a summary of your observations and recommendations based on each of the data metrics you've analyzed No bibliography is required Grading Criteria (note that grading is roughly equivalent to effort in each section): Quality Cost Analysis Ishikawa Diagram Process map Control Chart Pareto chart AQL Calculation . Observations & Recommendations Total Grade 10% 15% 15% 15% 15% 10% 20% 100%