$2\mathrm{.}1\mathrm{.}1$ Calculate the Risk Priority Number $($RPN$)$ for each failure mode.

$2\mathrm{.}1\mathrm{.}2$ Determine which four failure modes are the most important to analyse and

develop a control plan table for each.

QUESTION $3$

$3\mathrm{.}1$ Organisational Cost of Quality is categorised into four distinct cost spheres which

enable organisations to track and plan for quality financial requirements and

implications. Use the below case information to compile a Quality Cost Summary

report for this organisation for the previous month.

The quality control department comprises two inspectors who are primarily responsible

for finished goods inspection. There are three additional patrol inspectors who perform

first$-$off inspections on each production run. There is furthermore, one sorting inspector

who sorts lots rejected by final inspection. Quality inspectors are renumerated thus:

finished goods inspectors earn R$23000/$month$,$ first$-$off inspectors R$18000/$month$,$ and

reject sorters R$16000/$month$.$

The engineering department is responsible for, among other tasks, product and process

failures analysis, as well as control plan generation which cost roughly R$30000/$month$.$

An additional R$33000/$month is spent on previewing customer drawing specifications

and deriving quality requirements from them in order to establish quality specifications

for use by manufacturing personnel.

Scrap from final inspection rejects and customer returns amounted to $319000$ and

$233500$ pieces, respectively, for the past month. Customer returns requiring rework

average $150960$ pieces per month. Scrap generated during production is believed to be

approximately $60\%$ of the total floor scrap of $21000K\frac{g}{?}$ month. Final inspection rejects

an average of $111460$ re$-$workable pieces per month which are then flat rolled or re$-$

rolled. Finance has costed scrap items at R$66$ per thousand pieces, floor scrap at R$120$

per thousand kilograms, reworking of customer returns at R$98$ per thousand pieces, and

flat rolling and re$-$rolling at R$12\mathrm{.}20$ per thousand pieces.

$3\mathrm{.}1\mathrm{.}1$ Use the above preliminary data to compile a Quality Cost Summary $($QCS$)$ report

with percentage cost contributions inclusive therein.

$3\mathrm{.}1\mathrm{.}2$ Substantiate your recommendation for the top three Quality Improvement Projects

for the organisation using the results of the QCS$.$

QUESTION $4$