OPMT 1106: Quality Management Fundamentals Assignment #2 - due Mar 16, 2021 (by 6:30pm class time) You will submit files via Learning Hub Application of Knowledge Congratulations! You have just been hired by a company as their new Quality Manager. They are a large manufacturer of parts for the aerospace industry. The boss sits you down on the first day and indicates that "quality seems to be all over the place." He asks you to analyze the various parts of the process and provide some details and recommendations. He says "You've got your job cut out for you...good luck He gives you the following data for 3 of bad parts produced per day for the last month and the bad parts produced per machine in the last month Day Defects 1 2 Defects 17 15 29 20 4 5 6 7 8 9 10 Day 11 12 13 14 15 16 17 18 19 20 Defects 28 15 26 14 22 18 22 14 16 22 Day 21 22 23 24 25 26 27 28 29 30 18 22 22 16 17 23 20 24 16 22 19 Machine Defects per month 1 30 2 103 3 136 4 250 5 85 16 23 As a newly trained Quality Assurance Manager, you know that proper data analysis will be the first step You go visit Ray, the Production Supervisor, for an overview of the process. He says: "Well, we get the raw material from our suppliers. As it comes in, we do an inspection and if product is pood, it goes to the inventory arca. However, if it's bad it goes into our quarantine area to go back to the supplier. We got an order to make new parts, so we will pull the stock from inventory to one of our machines. The lead operator sets up the machine and then needs to get authorization the setup is ok. If it's ok, then we will run the order. If it's not theyredo it again until it is. Once the order is running, they will inspectin every 10 pieces. They assess this sample to make sure its ok to keep running. If the inspection is bad, they go back to working on the setup. Once the order is done. it's sent to shipping. They stap the onder and send it to the customer Pretty easy, really." You also find out they hired a consultant before you but she left before she was able to properly analyze the data and determine Upper and Lower control limits. However, the company, based on feedback from their customers, wants to see a goal of zero defects to a maximum of 10 per day As you continue your investigation, you find out there has been a brainstorming session before you arrived so they could try to understand the recent quality issues. They put together the ideas in the minutes but haven't done any other analysis with them so far. They are Our raw stock over the last few months seems to be getting worse 2. We got a lot of new operators over the last few months who've been pushed to the floor quickly 3. The dial on Machine No 4 is wom out and very hard to read 4. We've been using the samsetninger cars ago 5. I really don't know how they expect us check the sampics wien half the lights are burtout As you continue your investigation, you find out there has been a brainstoming session before you arrived so they could try to understand the recent quality assues. They put together the ideas in the minutes but haven't done any other analysis with them so far. They are 1. Our raw stock over the last few months seems to be getting we 2. We got a lot of new operates over the last few months who've been pushed to the floor quickly 3. The dial on Machine No 4 is wom out and very hard to read 4. We've been using the same specifications since I started here 10 years ago 5. I really don't know how they expect us to check the samples when half the lights are burtout above the machine...I can't see anything! 6. I don't know what the issue is -1 follow the standard procedures, same as John on Machine L. Not my fault the other guys do things their own way 7 I don't know how they expect the glue to hold when it's so cold in the warehouse 8. Machine No 3 has some very old parts that are loose 9. Bill is the only one who seems to know how to do the proper checks and he's off on sick leave 10. I'm told to do a different type of quality check by the designers, the supervisor and even the boss! 11. When setting up our dies, the wood used on the dies is himle and can crack causing issues 12. I've tried to check the depth of the finished goods, but the tape measures are all different Digging further, you determine that the organization has set up an MOL. for their inspections as per below Major Issue - AQL of 0.1 - with a lot size of 25.000 pieces and using General Level 2 Medium Issue - AOL of 0.65 - with a lot size of 25,000 pieces and using General Level 2 Minor Issue - AOL of 6.5 - with a lot size of 25.000 pieces and using General Level 2 Finally, you are given the following quality costs for the last year: Qualifications of Supplier Products 5675 Laboratory Support Process Control measurements 51960 Field Performance Evaluation S2555 Depreciation Allowance S2354 Review of Test and Inspection Data 5265 Measurement Equipment SSRS Inspection and Test Materials 5554 Purchasing Appraisal Costs SI55 Maintenance & Calibration labor S4558 Retrofit Costs $360 Warranty Claims 539,90 Recall Costs SOR.000 Disposition Costs Troubleshooting costs 538,675 Serap Costs $22.000 Material Review and CAR Costs 54.560 Supplier Reviews SI 200 Operator Quality Education $50 Contract Review $225 Quality Administration 5650 Now that you have everything, it's time to get to work! 5595 For this assignment, you must do the following Analyze the quality costs, separate cach one into each cost type and determine in each cost type. Do not round up or down-show to two decimal points be: 00.00%). Create an Ishikawa Diagram of the brainstormsession . For this assignment, you must do the following: Analyze the quality costs, separate each one into each cost type and determine % in cach cost type. Do not round up or down - show to two decimal points (i.e.: 00.00%). Create an Ishikawa Diagram of the brainstorm session Create a detailed flowchart of the process Create a control chart of the appropriate data - you must show your calculations and do not round up or down - show to two decimal points (i.e.: 00.00). Create a pareto chart of the appropriate data Calculate what the AQL information is Finally, on minimum two full pages to maximum three full pages (font size 12, single spaced), provide a summary of your observations and recommendations based on each of the data metrics you have analyzed (except the AQL data) No bibliography is required Grading Criteria . Quality Cost Analysis Ishikawa Diagram Flowchart of Process Control Chart Pareto chart AQL Calculation Observations & Recommendations 10% 10% 10% 10% 10% 10% 40% Total Grade 100% OPMT 1106: Quality Management Fundamentals Assignment #2 - due Mar 16, 2021 (by 6:30pm class time) You will submit files via Learning Hub Application of Knowledge Congratulations! You have just been hired by a company as their new Quality Manager. They are a large manufacturer of parts for the aerospace industry. The boss sits you down on the first day and indicates that "quality seems to be all over the place." He asks you to analyze the various parts of the process and provide some details and recommendations. He says "You've got your job cut out for you...good luck He gives you the following data for 3 of bad parts produced per day for the last month and the bad parts produced per machine in the last month Day Defects 1 2 Defects 17 15 29 20 4 5 6 7 8 9 10 Day 11 12 13 14 15 16 17 18 19 20 Defects 28 15 26 14 22 18 22 14 16 22 Day 21 22 23 24 25 26 27 28 29 30 18 22 22 16 17 23 20 24 16 22 19 Machine Defects per month 1 30 2 103 3 136 4 250 5 85 16 23 As a newly trained Quality Assurance Manager, you know that proper data analysis will be the first step You go visit Ray, the Production Supervisor, for an overview of the process. He says: "Well, we get the raw material from our suppliers. As it comes in, we do an inspection and if product is pood, it goes to the inventory arca. However, if it's bad it goes into our quarantine area to go back to the supplier. We got an order to make new parts, so we will pull the stock from inventory to one of our machines. The lead operator sets up the machine and then needs to get authorization the setup is ok. If it's ok, then we will run the order. If it's not theyredo it again until it is. Once the order is running, they will inspectin every 10 pieces. They assess this sample to make sure its ok to keep running. If the inspection is bad, they go back to working on the setup. Once the order is done. it's sent to shipping. They stap the onder and send it to the customer Pretty easy, really." You also find out they hired a consultant before you but she left before she was able to properly analyze the data and determine Upper and Lower control limits. However, the company, based on feedback from their customers, wants to see a goal of zero defects to a maximum of 10 per day As you continue your investigation, you find out there has been a brainstorming session before you arrived so they could try to understand the recent quality issues. They put together the ideas in the minutes but haven't done any other analysis with them so far. They are Our raw stock over the last few months seems to be getting worse 2. We got a lot of new operators over the last few months who've been pushed to the floor quickly 3. The dial on Machine No 4 is wom out and very hard to read 4. We've been using the samsetninger cars ago 5. I really don't know how they expect us check the sampics wien half the lights are burtout As you continue your investigation, you find out there has been a brainstoming session before you arrived so they could try to understand the recent quality assues. They put together the ideas in the minutes but haven't done any other analysis with them so far. They are 1. Our raw stock over the last few months seems to be getting we 2. We got a lot of new operates over the last few months who've been pushed to the floor quickly 3. The dial on Machine No 4 is wom out and very hard to read 4. We've been using the same specifications since I started here 10 years ago 5. I really don't know how they expect us to check the samples when half the lights are burtout above the machine...I can't see anything! 6. I don't know what the issue is -1 follow the standard procedures, same as John on Machine L. Not my fault the other guys do things their own way 7 I don't know how they expect the glue to hold when it's so cold in the warehouse 8. Machine No 3 has some very old parts that are loose 9. Bill is the only one who seems to know how to do the proper checks and he's off on sick leave 10. I'm told to do a different type of quality check by the designers, the supervisor and even the boss! 11. When setting up our dies, the wood used on the dies is himle and can crack causing issues 12. I've tried to check the depth of the finished goods, but the tape measures are all different Digging further, you determine that the organization has set up an MOL. for their inspections as per below Major Issue - AQL of 0.1 - with a lot size of 25.000 pieces and using General Level 2 Medium Issue - AOL of 0.65 - with a lot size of 25,000 pieces and using General Level 2 Minor Issue - AOL of 6.5 - with a lot size of 25.000 pieces and using General Level 2 Finally, you are given the following quality costs for the last year: Qualifications of Supplier Products 5675 Laboratory Support Process Control measurements 51960 Field Performance Evaluation S2555 Depreciation Allowance S2354 Review of Test and Inspection Data 5265 Measurement Equipment SSRS Inspection and Test Materials 5554 Purchasing Appraisal Costs SI55 Maintenance & Calibration labor S4558 Retrofit Costs $360 Warranty Claims 539,90 Recall Costs SOR.000 Disposition Costs Troubleshooting costs 538,675 Serap Costs $22.000 Material Review and CAR Costs 54.560 Supplier Reviews SI 200 Operator Quality Education $50 Contract Review $225 Quality Administration 5650 Now that you have everything, it's time to get to work! 5595 For this assignment, you must do the following Analyze the quality costs, separate cach one into each cost type and determine in each cost type. Do not round up or down-show to two decimal points be: 00.00%). Create an Ishikawa Diagram of the brainstormsession . For this assignment, you must do the following: Analyze the quality costs, separate each one into each cost type and determine % in cach cost type. Do not round up or down - show to two decimal points (i.e.: 00.00%). Create an Ishikawa Diagram of the brainstorm session Create a detailed flowchart of the process Create a control chart of the appropriate data - you must show your calculations and do not round up or down - show to two decimal points (i.e.: 00.00). Create a pareto chart of the appropriate data Calculate what the AQL information is Finally, on minimum two full pages to maximum three full pages (font size 12, single spaced), provide a summary of your observations and recommendations based on each of the data metrics you have analyzed (except the AQL data) No bibliography is required Grading Criteria . Quality Cost Analysis Ishikawa Diagram Flowchart of Process Control Chart Pareto chart AQL Calculation Observations & Recommendations 10% 10% 10% 10% 10% 10% 40% Total Grade 100%