By using 7 quality control tool

CASE STUDY – SEVEN QUALITY TOOLS Task : 

TO REDUCE THE WARRANTY CLAIM AND SUSTAIN THE COMPONENTS QUALITY

PLASTIC AND DASHES SDN.

Plan phase 

STEP 1 : Problem statement 

Plastics and Dashes Inc. (P&D) supplies instrument panels and other plastic components for automobile manufacturers. Recently their largest customer informed them that there have been an excessive number of customer complaints and warranty claims concerning the P&D instrument panel. The warranty claims have amounted to over RM 200000, including the cost of parts and labor. 

STEP 2: Team Members 

STEP 3: 

After discussion, they have decided to investigate each warranty claim from preceding six months. Once all the warranty information and data has been reviewed, they found that the number of nonconformities are: batch 1 - loose instrument (355), noisy instrument (200), electrical problem (110), improper installation (80), inoperative instrument panel components, (65) and warped instrument panel (45). Batch 2: loose instrument (250), noisy instrument (10), electrical problem (80) , improper installation (60), inoperative instrument panel components, (20) and warped instrument panel (50). The costs associated with the nonconformities are: loose instrument (RM 115000), noisy instrument (RM 25000), electrical problem (RM 20000), improper installation (RM 15000), inoperative instrument panel components, (RM 5000) and warped instrument panel (RM 2800). 

STEP 4: Developing Performance Measures 

The management team will tracking the number of warranty and financial cost data in order to know whether or not the improvement steps are working. 

STEP 5: Analyzing the Problem/ Process 

Transfer retainer and pad – insert both material on A/C outlet – Prepare glove box and assemble the A/C outlet – attach air bag – inspection- packing-shipping 

STEP 6: Determining Possible Causes 

Continue Do, Check and Action Phases.