WSU Supply Chain Management - Quality Case Study - October 2023 With its railroad access and presence of numerous automobile factories, Milwaukee Juncon was considered the cradle of the automove industry at the turn of the 20 th century. Now, 100 years later, the automove industry looks to make Milwaukee Juncon 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 automove industry. The Milwaukee Juncon Revitalizaon Project is not only significant to the next generaon of automobiles, but the success of the facilies is crical to the resurgence of Detroit and Southeast Michigan. You've been selected to be part of the team that will stamp automove washers in a reclaimed, historic automove facility on Piquee 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 menoned before, your facility has 20 high speed presses, and you are responsible for launching a compound die that will be responsible for stamping 5M 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 enre 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 producon. All data you need will be taken from a preliminary part run, aer which you will report the results to your customer. The following informaon will be used to complete your part approval. Part specificaons: Outside Diameter: 55 mm 5 mm Inside Diameter: 20 mm 5 mm Material Thickness: 0.5 mm 0.1 mm Material Chemistry: See Material Cert Incoming Material: Coil Width: 60 mm Material Thickness: 0.5 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 tesng - 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 situaons. No worries - this happens all the me, and you should be thankful that it's occurring before you get too far in producon. Review the content from above and apply the changes idenfied 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 operang paern, you will need to buy another press and build a new die to stamp the now 7M parts required each year. Complete a part approval for the new press, known as Press 21, and die and submit those results with the exisng 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 enrely 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 sll 5 mm. Complete the part approval for the new diameter of the part. All submissions will be submied 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. - - Inial PPAP - October 2023 2. - - Change Scenario 1 PPAP - October 2023 3. - - Change Scenario 2 PPAP - October 2023 4. - - Change Scenario 3 PPAP - October 2023 5. - - Change Scenario 4 PPAP - October 2023