Material Science Engineering class regarding quality control.
Company ABC Inc. manufactures electrical sensors for the aerospace industry. This company has been the leader in the industry for the last 20 years. However, Competition got smarter and business is not as good as it was.
The Vice President and the Quality Director at ABC Inc. realize that there is not a good, solid, preventive Root cause Analysis and Corrective Action system in place. The Company operates on a “fire-fighting” mode to respond to customer complains, and returns.
Your group is given the project to develop a plan to implement a Root cause/Corrective action system. The plan is due December 2015.
Technical and detailed information is not provided, with the purpose to create a plan to be of a “generic format”.
Initial assumptions:
1- ABC Inc is “medium” size (300 employees). Support groups (Quality engineering, Mfg Engineering, etc) constitute 30% of the work force.
2- Manufacturing rate is 2,000 sensors per week. The company produces 4 different models of sensors through 4 successive work stations A, B, C, and D with equal work load (25% each).
3- External customers’ rejection yield is 25%. Rejection rate internally is15%
4- The company has a “weak” QMS in place.
5- The company is willing to invest 15,000 – 20,000 man-hours in this project (including training, pilot programs…etc), if needed.
Deliverables from the project:
1- List of assumptions and justifications
2- Detailed action plan to meet deadline of Dec 2015
3- Procedure to execute Root cause analysis and corrective actions (RCCA)
4- Definition of a System to measure effectiveness of this RCCA system
5- Written report. Minimum 3000 words