Background

Investigation

Hank Kolb:
o Hired 4 weeks
o Director,Quality assurance
o Company-->Industrial products plant(1200people)
o Greasex Line-->Aspecialized degreasing solvent packed in a spray can for hitech sector
Mark Hamler info:
o (v)tech knowledge (x) managerial skill
o just another typical snafu
o a little high pressure in cans@2ndshift:new filling equipt.+cans->pressured beyond USL(50%off),14 cases/shift+cough halfway
Wayne Simmons info:
o Seal-up rejects --> remove 'hold'
o turn cans upside down+vented--> production planning--> can't
delay,can't rework

Heda
Kalenia
YP55B
291160
56

Mac Evans info:

o <USL --put tag'hold' = rejects -->didn't write it up
o to be told to send it to rework div.
Problems
@OM

Hank
Kolb,Direct
or, Quality
Assurance

Safety issue on the high pressured in the cans, caused by defect design.
Added with there isn't quality value on employee.

Problems
@Division

Solution

o
o
o

Investigate how the machine can sometime be high

pressure
Give employee (advise) clear understanding about the cost
of poor quality Vs the good one
Senior management have to be bold+follow-up full
production to change employee attitude

Personnel:
o Operator filling eq. from shipping, 2
wk ago (transferred)
o Trained by Wyne
o Mac tested high pressure cans -->
operator is nowhere
o Learned the rejected material from
Wayne after shift
Plant Maintenance:
o Piece of automated filling purchased 2yr
ago--> use on other product--> no
schedule preventive maintenance
o Switch to greasex line 6months ago,
replaced 3 times, made@nearby
machine shop
o Maintenance 12 work orders
oPurchashing:
Equioment probs: lower vicosity of
o Plastic
nozzle
head-->
design
greasex,
sensitive
filling
head,by
vendor-->rush
order-->slight
burrs-nonstandard downtime
running
@15%
>inside
rim-->
trouble
in
fitting
of actual
Manufacturing Manager:
o The manager underpressure from
Morganthal
for
cost
improvements+reduced delivery times

Product design + packaging:

o Greasex seen significant by the designers -->no test of contoured can effect ->filling speed/hydrodynamics -->high pressured fillinghead.
o kolb hunch: new design-->as venturi-->when being filled-->designer:unlikely
Marketing:
o Greasex introduction-->rushed-->major
promote.ads underway to increase
consumer awareness
o A deluge of orders was swamping the

Product Design+
Packanging
Division

high pressured fillinghead, act as venturi when being filled

no test of contoured can effect
Failed cans design

Purchashing Division
Unfitting plastic
nozzle head

Plant Maintenance
Division

Slight burrs
inside rim

Replaced 3 times
Made@
nearby machine shop

underpressure from
Morganthal
for cost
improvements+
Reduced
delivery times

Company

Broken automated filling

Switch to greasex
line 6 mnth ago

Rush orders

PIC Attitude

High-pressure
on some cans

Swamping orders

lack
of quality attitude
Beyond USL
(50%OFF)

14 cases/shift,
caugh halfway

Been used on
other product

Mac Evans
didnt write
the rejects cans

Rushed

Wayne Simmons
seal-up
the rejects
Remove taghold+vented

Quality as
secondary
added value

Downward Quality-Productivityturnover spiral

Hamler didnt care about high-pressure
on some cans as long as orders fullfilled
Cant rework+cant delay

Cans below USL-tag hold

Manufacturing
Manager Division

Lack of commitment to
achieve excellent
quality product

Production planning
Big Promote-ads

Marketing Division

Personnel division

PIC Action Problem