Question: A window handle model, shown opposite, manufactured using a gravity die casting process operation has shown to have a very high rejection rate. Today the
A window handle model, shown opposite, manufactured using a gravity die casting process operation has shown to have a very high rejection rate. Today the quality and aesthetics expectations require significant process improvements. The components are produced in low silicon aluminium and finished with an anticorrosion anodising process that supports low maintenance. Many of the defects are only detected at the end of the manufacturing process. The problems of late detection and high rejections to lead to significant waste and cost factors, including: Waste of time and unnecessary consumption of resources in processing defective items. Extensive rework prevents other products to be manufactured, creating two additionalproblems: To satisfy the specified service levels to the customer, the levels of safety stocksneed to be higher, which increases the holding costs. The company has more difficulties in complying with the necessary lead time todeliver ontime the order demanded by the customer. The waste factors result in additional labour, materials, and energy consumption costs,among others. Nonquality costs resulting from the lack of capability of the process in meeting the productspecifications Intangible costs, including image and reputation costs. The sales of anodized aluminium architectural hardware represent of the companysturnover and it is growing. Depending on operators experience and other unknown factors occasionally sometimes theproduction yield was higher.The company decided to select this as a Six Sigma project using the DMAIC approach.Project planningPlanning is a prior stage that takes place before the DMAIC roadmap is initiated. It intends to reach a clear understanding of the problem and detailed project planning tasks. JAWS Ltd needs support to analyse the preliminary data and enable the team to develop the project charter and communicate the relevant information about the Six Sigma project.
Complete the project scoping schedule document in the table below by providing a description of the project documentation areas.
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