WA Classroom Assignment PTAC 2314 Fall 2019 1. Each team will determine the cause of the primary problem described below. Use the Apollo Root Cause Methodology process to define the primary problem. (Use Table 8-3 and Table 8-4 on page 136-137 from your text book Process Quality as an example.) 2. Using BRAINSTORMING techniques develop potential causes for the primary problem. At least 50 potential causes should be identified. 3. Group your potential causes into the five categories of a Fishbone Diagram: Manpower Machines, Materials, Methods and Environmental. Create a Fishbone Diagram for the defined primary effect on chart paper. 4. Teams will complete work on the problem during the next class period, but each team should complete the fishbone analysis prior to the next class period 5. Based on your completed Fishbone Analysis, determine the Root Cause of the problem using the Apollo methodology. Provide a Cause and Effect Diagram for your problem definition on chart paper. Clearly provide the Root Cause statement. This should be a sentence that provides the problem statement and why the problem occurred, including what, when, where, who, and why. An example of an acceptable Root Cause Statement is: The burn injury to the XYZ contract employee which occurred at 1:30 p.m. on March 31, 2018, at the Isopropanol Unit Building 54, was due to the failure of the steam nozzle on the pressure hose being used to clean a heat exchanger during shutdown activities. Note: It is acceptable to identify a root cause with contributing factors. The contributing factors should be identified in your Root Cause statement as additional sentences. 6. Determine the best two solutions that will result in problem resolution from a list of solutions that the team creates. One of the solutions should be a short term solution that can be fully implemented within one month. The other solution should be a long term solution that can be fully implemented within six months. These solutions should also be shown on chart paper. 7. By implementing the solutions, no recurrence of the problem should occur. 8. Lastly, the team will present its solution to the class showing and discussing its work on the chart paper. PROBLEM: "Light-Weight" Shipments Don't Measure Up: Several customers have lodged complaints with your business' Customer Service Representative of polyethylene pellet hopper car shipments from your plant during the last three months. The complaints indicate that shipments are consistently 5% or more below the requested and purchased weight. There have been no reported complaints of shipment weights on hopper truck shipments during this same time frame. This inaccurate shipment weight issue is damaging the reputation of your business and must be addressed promptly because several future shipment orders have been cancelled. Your business leader patiently awaits your report which will include your findings, the root cause for the inconsistent shipment weights, both short and long term solutions to the problem, and the process you used to reach the conclusion. WA Classroom Assignment PTAC 2314 Fall 2019 1. Each team will determine the cause of the primary problem described below. Use the Apollo Root Cause Methodology process to define the primary problem. (Use Table 8-3 and Table 8-4 on page 136-137 from your text book Process Quality as an example.) 2. Using BRAINSTORMING techniques develop potential causes for the primary problem. At least 50 potential causes should be identified. 3. Group your potential causes into the five categories of a Fishbone Diagram: Manpower Machines, Materials, Methods and Environmental. Create a Fishbone Diagram for the defined primary effect on chart paper. 4. Teams will complete work on the problem during the next class period, but each team should complete the fishbone analysis prior to the next class period 5. Based on your completed Fishbone Analysis, determine the Root Cause of the problem using the Apollo methodology. Provide a Cause and Effect Diagram for your problem definition on chart paper. Clearly provide the Root Cause statement. This should be a sentence that provides the problem statement and why the problem occurred, including what, when, where, who, and why. An example of an acceptable Root Cause Statement is: The burn injury to the XYZ contract employee which occurred at 1:30 p.m. on March 31, 2018, at the Isopropanol Unit Building 54, was due to the failure of the steam nozzle on the pressure hose being used to clean a heat exchanger during shutdown activities. Note: It is acceptable to identify a root cause with contributing factors. The contributing factors should be identified in your Root Cause statement as additional sentences. 6. Determine the best two solutions that will result in problem resolution from a list of solutions that the team creates. One of the solutions should be a short term solution that can be fully implemented within one month. The other solution should be a long term solution that can be fully implemented within six months. These solutions should also be shown on chart paper. 7. By implementing the solutions, no recurrence of the problem should occur. 8. Lastly, the team will present its solution to the class showing and discussing its work on the chart paper. PROBLEM: "Light-Weight" Shipments Don't Measure Up: Several customers have lodged complaints with your business' Customer Service Representative of polyethylene pellet hopper car shipments from your plant during the last three months. The complaints indicate that shipments are consistently 5% or more below the requested and purchased weight. There have been no reported complaints of shipment weights on hopper truck shipments during this same time frame. This inaccurate shipment weight issue is damaging the reputation of your business and must be addressed promptly because several future shipment orders have been cancelled. Your business leader patiently awaits your report which will include your findings, the root cause for the inconsistent shipment weights, both short and long term solutions to the problem, and the process you used to reach the conclusion