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Denver Facility problems

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The following is a large and cumbersome task therefore I have provided the maximum points and time allotted for assistance. It seems like it is quite difficult or involved but if you disect the issues piece by piece they all fall into place and are not as intimidating. However, I am referring for any assistance as this is still a large and complex task. Attached is the scenario for the organization and trip notes for assistance in task completion.

Task details

One Tuesday morning, your supervisor, Mr. Walters, has assigned you to investigate the product quality issues at the Denver facility. He summarized what little he knows by saying:
"The Denver facility produces a wide variety of liquid chemical products. Raw materials arrive at the Denver facility by railroad tank car. Most shipments are made in single or multiple compartment semi-trailer tankers.
? Denver is having problems with delivered product quality
? Their production systems appear to be out of control at times.
? There are too many (non-Canbide) vehicles driving through the plant. It does not seem that those drivers are fully aware or observant of the proper safety measures to be followed in case of a plant emergency
? The Denver community relations office has been getting many complaints from neighborhood residents and from the local police station about trucks blocking the streets in front of the plant, awaiting clearance to enter the plant. The road blockages are usually short lived, but they consistently occur during the morning and late afternoon drive times
? Our automotive customers are insistent that the laboratory testing report on each SKU accompany each shipment. The Denver laboratory is reportedly very slow in producing those lab reports
? Trucks carrying noncompliant products have been released from the Denver facility, with a lab report that says the products are non-compliant
? The plant transportation operations group (dispatching and scheduling) does not know when trucks will arrive at the front gate
? About 20% of the trucks arrive with no advance notice and with no order on file, but with purchase order in hand
? Denver periodically runs out of certain products without warning
? The facility has requested funds to build a new truck scales, but the need has never been justifiable on a cost/benefit basis."
Please refer to the file, Denver Trip Notes, for details of your visit to the Denver facility.
Part 1:
Conduct a root cause analysis of the various issues that Mr. Walters presented. As you analyze these issues, you will recognize that they to some degree are all inter-related. Discuss how the performance of the various areas impacts one another. Identify upon a reasonable solution(s) to address the problem(s) Determination will need to be made on beneficial solutions.
Part 2:
Draft a trip report for Mr. Walters of your group's preliminary recommendations. Be sure to clearly identify the underlying (root) cause of the problems and provide a reasonable and acceptable solution. Since this report is going only to your boss, and not the plant manager, your explanations should be complete and to the point. If possible, you should identify who at the plant should be responsible for implementing the final solutions.
The trip report should include the following sections: Dispatching, Transportation and Scheduling; Quality Control Laboratory; Production Units and Operational Departments; Product Loading Facilities and Operations; Product Loading of Polyols.
In addition, reflect upon and critique any recommendations made by individuals. Address any issues you felt the solution would not resolve, your rationale for why it would not resolve the issue, your suggested revisions and rationale to support the suggestion.

To assist in formulation of assignment and research of pinciples/variable please list any/all resources. Thank you for your time and assistance with this complex task!

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Denver Facility problems

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Root cause analysis of the various issues

Background:
The Denver facility produces a wide variety of liquid chemicals.
Raw materials arrive at the Denver facility by railroad tank car.
Most shipments made in single or multiple compartment semi-trailer tankers.

Scenario:
Problems with delivered product quality
roduction systems appear to be out of control at times
Too many (non-Carbide) vehicles driving through plant.
Appears that drivers are not fully aware or observant of proper safety measures
Neighborhood residents and police complaining of trucks blocking the streets in
front of the plant.
Road blockages are normally short lived but consistently occur in the morning and late afternoons.
Automotive customers require that laboratory testing report on each SKU accompany each shipment. Denver facility is slow in producing lab reports.
Noncompliant trucks leaving Denver facility with lab reports stating that the products are non-compliant.
Plant transportation operations group (dispatching and scheduling) does not know when trucks will arrive at the gate.
20% of trucks arrive with no advance notice and with no order on file, but with purchase order in hand.
Denver periodically runs out of products without warning.
Denver facility has requested funds for new truck scales, but the need was not justified on a cost/benefit basis.

Problem:
Conduct a root cause analysis of the various issues that Mr. Walters presented
Discuss how the performance of the various areas impacts one another.
Come up with solutions

Draft a trip report for Mr. Walters of your groups preliminary recommendations.
Identify the underlying root cause of the problems and provide a reasonable and acceptable solution along with a trip report to include the following.

1. Dispatching 2. Transportation & Scheduling 3. Quality Control Laboratory
4. Production Units & Operational Departments 5. Product Loading
6. Facilities & Operations 7. Product Loading of Polyols

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