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¶ … president?
I would inform the president that the increase in the defect rate must be related to an assignable cause. If there was no change in the overall process, then there must some small deviation in the chain of operations included in the process. For example, while there may not have been a change in the process for die cutting, it could be possible for one of the dies to have become wrapped or one of the machines to become out of alignment. Other examples that may explain the defects would be a variation in the raw materials or other imputes that go into the process as well as a countless number of other possible attributable causes.
Furthermore, I would explain that a systematic approach must be taken to figure out what explains the defects in the production process. Through a deductive approach it is feasible that the issue can be quickly identified. One obvious way to track the products quality is to follow from stage to stage in the production process and continuously...
This is usually enough to figure out what stage in the process is creating the errors and then once the stage has been identified further investigation should be able to identify the particular problem.
2. He wants you to change the process to reduce the number of defects, but you know that is the wrong approach. How do you talk him out of it?
I would desperately try to talk him out of trying to redesign the whole process. The first thing I would mention is that no process is entirely perfect. Each process takes time and energy to put together and bugs in the process are worked out along the way. Thus processes have sort of an evolutionary aspect to them. They are first designed and redesigned to meet their requirements. Each redesign in the process represents a valuable contribution. Thus if you start all over by building a new process you will lose the value in the existing design.
In many cases, companies…
Works Cited
IMF. (n.d.). TQM Tools. Retrieved from Institute for Manufacturing: http://www.ifm.eng.cam.ac.uk/dstools/represent/tqm.html
Malik, S. (2007, May 2). Creating Departmental Dashboards. Retrieved from Dashboard Insight: http://www.dashboardinsight.com/articles/digital-dashboards/building-dashboards/departmental-dashboards.aspx
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