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Use of Diagrams in TQM

The The Excellent Manufacturing Company is experiencing quality problems with its Brak-Et line. Rejects and rework have started to go above the 10% level. This is now costing more than $50,000 per month in scrap and rework. The Mfg Engr. Dept. decided to do a Six Sigma project and reduce these excessive costs of poor quality that the Brak-Et is now generating. They developed an overall plan which includes the Definition of the problem and the Measurement phase (a Data Collection plan).

Project Definition: the Brak-Et product line and the four manufacturing processes of blanking, grinding, plating and assembly. To reduce the quality costs from 10% to 2%.

Project Measurement plan: Collect data regarding rejects and rework at the four different processes and determine where the major issues and biggest problems existed. This data is available in terms of $ of rework and $ of scrap. Then for those major categories, brainstorm and identify the possible causes of these major issues. And then finally, collect data for related factors to determine if there are any strong correlations between the quality problem and production settings.

The major categories of quality issues for the first data collection are: blanking scrap, blanking rework, grinding scrap, grinding rework, plating scrap, plating rework, assembly scrap, and assembly rework.

For each manufacturing process there are several factors that can influence the output and its quality, such as machine speed, power setting, and tool force. Each of these can be measured on a continuous scale and are known to vary somewhat from time to time.

Assignment: Given this information about the Excellent Mfg. Co., develop a detailed plan for Measurement and Data Collection using the three quality tools (Pareto, Scattered, Fishbone).

Assignment Expectations: Discuss each tool, how it should be used, what data would be included, and what you would do with the data. These three tools should be used sequentially, so think about which one would be used first, how its results would then be used as input into the second tool and then how those results could be used as input into the third tool. Discuss each tool, how it should be used, what data would be included, and what you would do with the data.

Write a one page paper using good form and format and submit. The main focus of the paper is on the use of the three quality tools, but you may add any additional information that will help to clarify the problem. Be sure to include your references.
Required

Pareto Diagram

American Society for Quality. (2009). Pareto Diagram. Excerpted from Nancy R. Tagueâ??s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, pages 376-378. Retrieved from http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/pa reto.html

Armstrong, F.E. (2008). Tool #2 - The Pareto Diagram, from Beginner's Guide: The 7 Basic Quality Tools. Retrieved from http://thequalityweb.com/pareto.html

Cause & Effect Diagram

American Society for Quality. (2009). Fishbone Diagram. Excerpted from Nancy R. Tagueâ??s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, pages 247-249. Retrieved from http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/fi shbone.html

Armstrong, F.E. (2008). Tool #4 - Cause-and-Effect Diagram, from Beginner's Guide: The 7 Basic Quality Tools. Retrieved from http://thequalityweb.com/cause.html

Scatter Diagram.

American Society for Quality. (2009). Scatter Diagram. Excerpted from Nancy R. Tagueâ??s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, pages 471-474. Retrieved from http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/sc atter.html

Armstrong, F.E. (2008). Tool #5 - The Scatter Diagram, from Beginner's Guide: The 7 Basic Quality Tools. Retrieved from http://thequalityweb.com/scatter.html is experiencing quality problems with its Brak-Et line. Rejects and rework have started to go above the 10% level. This is now costing more than $50,000 per month in scrap and rework. The Mfg Engr. Dept. decided to do a Six Sigma project and reduce these excessive costs of poor quality that the Brak-Et is now generating. They developed an overall plan which includes the Definition of the problem and the Measurement phase (a Data Collection plan).

Project Definition: the Brak-Et product line and the four manufacturing processes of blanking, grinding, plating and assembly. To reduce the quality costs from 10% to 2%.

Project Measurement plan: Collect data regarding rejects and rework at the four different processes and determine where the major issues and biggest problems existed. This data is available in terms of $ of rework and $ of scrap. Then for those major categories, brainstorm and identify the possible causes of these major issues. And then finally, collect data for related factors to determine if there are any strong correlations between the quality problem and production settings.

The major categories of quality issues for the first data collection are: blanking scrap, blanking rework, grinding scrap, grinding rework, plating scrap, plating rework, assembly scrap, and assembly rework.

For each manufacturing process there are several factors that can influence the output and its quality, such as machine speed, power setting, and tool force. Each of these can be measured on a continuous scale and are known to vary somewhat from time to time.

Assignment:

Given this information about the Excellent Mfg. Co., develop a detailed plan for Measurement and Data Collection using the three quality tools (Pareto, Scattered and Fishbone).

Assignment Expectations: Discuss each tool, how it should be used, what data would be included, and what you would do with the data. These three tools should be used sequentially, so think about which one would be used first, how its results would then be used as input into the second tool and then how those results could be used as input into the third tool. Discuss each tool, how it should be used, what data would be included, and what you would do with the data.

Required

Pareto Diagram

American Society for Quality. (2009). Pareto Diagram. Excerpted from Nancy R. Tagueâ??s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, pages 376-378. Retrieved from http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/pa reto.html

Armstrong, F.E. (2008). Tool #2 - The Pareto Diagram, from Beginner's Guide: The 7 Basic Quality Tools. Retrieved from http://thequalityweb.com/pareto.html

Cause & Effect Diagram

American Society for Quality. (2009). Fishbone Diagram. Excerpted from Nancy R. Tagueâ??s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, pages 247-249. Retrieved from http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/fi shbone.html

Armstrong, F.E. (2008). Tool #4 - Cause-and-Effect Diagram, from Beginner's Guide: The 7 Basic Quality Tools. Retrieved from http://thequalityweb.com/cause.html

Scatter Diagram.

American Society for Quality. (2009). Scatter Diagram. Excerpted from Nancy R. Tagueâ??s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, pages 471-474. Retrieved from http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/sc atter.html

Armstrong, F.E. (2008). Tool #5 - The Scatter Diagram, from Beginner's Guide: The 7 Basic Quality Tools. Retrieved from http://thequalityweb.com/scatter.html

Solution Preview

I have attached a file with some charts that you can fill in based on your scenario. I began two of them to show you how to use them. The scatter plot has no information because there is no data in the scenario to use. I did make up some figures for the Pareto chart to show how it would be used. If you have any questions about the assignment or need further help, please ask.

The use of charts is important to organize the problems in logical ways and to provide visual ways to analyze the problems. I would use the fishbone, then the ...

Solution Summary

This solution of 357 words includes three diagrams and explanations of their use in TQM situations. References used are included in the answer.

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