Hank Kolb

Fishbone Diagram

Personnel with lack of quality attitude

Equipment’s performance is failing

Personnel Equipment

Inadequate equipment

Lack of training to machine operator

No scheduled preventive maintenance

Not taking immediate actions to resolve the problems

Greasex cans “rejects”

Nozzle heads with burrs that prevent proper fitting

Need to make on time deliveries and cost improvements

Inefficient communication between managers and employees through-out the production plant

Design of the can was not tested by engineers

Increased demand need to be met

Intense pressure to meet production quotas

Product Design Production Management

Continuous Improvement Program

* Implementing a total quality management strategy within the organization that ensures the involvement and cooperation of the entire workforce.

* Developing quality specifications for the Greasex product by reviewing the design quality, conformance quality, and quality of the source. This means that the design and packaging department will need to address the issue of the burrs in the nozzle heads with the vendor and get it resolved, testing will need to be performed on the design of the cans to ensure that the aesthetics is not an issue for the product filling, the product specs will be clearly defined and production will need to comply with these standards, and the personnel will take responsibility over the quality of the product.

* Analysis and testing will be necessary to identify the most influential causes of the greases rejects and a project plan will need to be put in place to address each of these issues.

* Utilizing multiple tools, such as charts, checklists and diagrams that show the performance of the various processes involved in the Greasex production: employee metrics, defects found by the inspector, number of times that a product had to be reworked, cost of scrapped product, etc. This...