Case Study:

Defect In Door Panels Observed At Assembly Facility​​

Project Analysis :

Problem :

Slits were formed in the window frame of door panels during transport to the assembly facility.

Resolution :

Through statistical analysis (Shainin method) it was found the elongation value of the metal was within range but on the low end. As a result minor slits or defects were formed n the window frame. The resulting slits found at the assembly facility went undetected at the assembly facility. As a result the elongation value became a key performance indicator (KPI) for incoming material. New control limits were established for the material that allowed the material to be processed with satisfactory and consistent results (stable process).

Finanacial :

Due to the elongation value the purchaser was credited $500,000 in scrap material. Not counting the loss in downtime at the manufacturing and assembly plant.

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