Autoplant Summary

The problem that needed to be solved is in plant that produces quarter panels (the successor to the fender & the part that often damage in collision in traffic accident). The panel produced in 4 line of production, which each line headed by the hydraulic press those stamps the panels out of sheet steels blanks.

To fulfill the customer satisfaction, the plant manager and the three subordinate have to find out why the panel that has produced is appearing burrs and rough spots, which causing panels being rejected. To identify the problem they arrange emergency meeting, which discuss about the reason why the burrs and rough spot were appearing on many panels. They suspect that it caused by sabotage that has done by the operators in production line, because personnel problem between Farrell and Valenti, which make an outspread, affect the union.

Problem: Nearly 10 % of the panels coming off lines #1 and #2 were being rejected by QC because of burrs and other rough spots

- Because there are many rejected in some production and it give an effect to the following process and makes the production stop at the time.

- Midnight shift: high rate of rejected

Potential Cause: production, labor, and personnel

1. What can you see that causes you to think there's a problem?

2. Where is it happening?

3. How is it happening?

4. When is it happening?

5. With whom is it happening? (HINT: Don't jump to "Who is causing the problem?" When we're stressed, blaming is often one of our first reactions. To be an effective manager, you need to address issues more than people.)

6. Why is it happening?

Write down a five-sentence description of the problem in terms of "The following should be happening, but isn’t..." or "The following is happening and should be: ..." As much as possible, be specific in your description, including what is happening, where, how, with whom and why. (It may be helpful at this point to use a variety of research methods.