WSU Supply Chain Management $$ Quality Case Study $$ October $2023$

With its railroad access and presence of numerous automobile factories, Milwaukee Junc$$on was

considered the cradle of the automo$$ve industry at the turn of the $20$th century. Now, $100$ years later,

the automo$$ve industry looks to make Milwaukee Junc$$on the launchpad for its next century of growth

and development. Instead of wooden horse carriages and body shops, electric vehicle components will

be manufactured in this historic industrial hub.

As Wayne State students, you understand Detroit and what it takes to thrive in the City of Champions

and home of the automo$$ve industry. The Milwaukee Junc$$on Revitaliza$$on Project is not only

significant to the next genera$$on of automobiles, but the success of the facili$$es is cri$$cal to the

resurgence of Detroit and Southeast Michigan.

You$$ve been selected to be part of the team that will stamp automo$$ve washers in a reclaimed, historic

automo$$ve facility on Pique$$e Avenue. The plant will have $20$ high speed stamping machines that will

produce washers and special components for EV motor assemblies. The $$ming for this launch is almost

as $$ght as the part tolerances, but it$$s nothing that is insurmountable.

As men$$oned before, your facility has $20$ high speed presses, and you are responsible for launching a

compound die that will be responsible for stamping $5$M washers per year. The press, known as Press $20,$

will run at capacity, which includes appropriate $$me for die maintenance, and will be dedicated to this

die for the en$$re year. To be clear, Press $20$ does not have capacity for any more parts.

To launch the product, you$$ll need to complete the following tasks to receive approval from your

customer to begin produc$$on$.$ All data you need will be taken from a preliminary part run, a$$er which

you will report the results to your customer. The following informa$$on will be used to complete your

part approval.

Part specifica$$ons:

$$ Outside Diameter: $55$ mm $\backslash$pm $5$ mm

$$ Inside Diameter: $20$ mm $\backslash$pm $5$ mm

$$ Material Thickness: $0\mathrm{.}5$ mm $\backslash$pm $0\mathrm{.}1$ mm

$$ Material Chemistry: See Material Cert

Incoming Material:

$$ Coil Width: $60$ mm

$$ Material Thickness: $0\mathrm{.}5$ mm

Process Parameters:

$100$ strokes per minute

$$ Dies sharpened every $75,000$ cycles

$$ Die perishable details are replaced every $500,000$ cycles

$$ Die gaps: $10\%$ of material thickness

Packing:

$125$ pieces per box

$$ Nine boxes per pallet layer

WSU Supply Chain Management $$ Quality Case Study $$ October $2023$

$$ Five layers on the pallet

Process Steps:

$$ Receiving

$$ Stamping

$$ Pack & Count

$$ Shipping

To achieve part approval, you will need to complete the following items $($blank forms are included$)$:

$1.$ Process flow chart

$2.$ Control Plan $($include process and product parameters$)$

$3.$ Part Layout $($six parts$)$

$4.$ Material Results $($chemistry $$ from cert$)$

$5.$ Test Results $($material physical tes$$ng $$ from cert$)$

$6.$ PSW warrant.

Once you complete all these documents, you will assemble them as a PDF package and present your

results to the remainder of your team and see if your customer$/$professor signs off on your PPAP.

Unfortunately, the following scenarios occur, and you need to complete new part approvals for each of

these situa$$ons$.$ No worries $$ this happens all the $$me$,$ and you should be thankful that it$$s occurring

before you get too far in produc$$on$.$ Review the content from above and apply the changes iden$$fied in

each scenario, but be smart and see what can be common and what needs to be recreated:

$1.$ Good news! Your washers are a success, but your customer needs more of them. Based on your

opera$$ng pa$$ern$,$ you will need to buy another press and build a new die to stamp the now $7$M

parts required each year. Complete a part approval for the new press, known as Press $21,$ and

die and submit those results with the exis$$ng results to your customer.

$2.$ Your steel supplier just informed you that they are increasing your pricing by $75\%,$ so you have

decided to find a new supplier. Complete the part approval process for this new steel supplier.

$3.$ Bad news $$ your building has a leak. As it$$s an old building, you$$re not en$$rely surprised, but you

cannot let the leak ruin your machine and tooling. You$$ll have to move your press so it$$s not

under the leak and complete all the approval process for the change.

$4.$ Engineering changes occur all the $$me$,$ and your customer just changed the outside diameter of

your washer from $55$ mm to $60$ mm$.$ No worries $$ the tolerance is s$$ll $\backslash$pm $5$ mm$.$ Complete the

part approval for the new diameter of the part.

All submissions will be submi$$ed in a PDF file to your customer$$s supplier quality engineer, Dr$.$ Rightmer.

Dr$.$ Rightmer will review and either approve or reject your part submission based on the completeness

and accuracy of the data you provide. Please label each submission accordingly:

$1.--$ Ini$$al PPAP $$ October $2023$

$2.-$