Only question 3 needs to be answered, thank you Font Paragraph The Climanto Moto

Question

Only question 3 needs to be answered, thank you Font Paragraph The Climanto Motor Company manufactures motors for automobile air conditioners in a fully automated plant which has been in operation for only two years. Many "bugs have been worked out during this time and quality costs have been reduced, but they still appear to be at too high a level from management's viewpoint. As a consultant, you have been asked to give your views as to whether quality cost reduction is feasible, and if so, what steps ought to be taken You have succeeded in having a Quality cost picture compiled as shown in the attached exhibit, and have also surveyed the operations and compiled the following notes: 1. The company employs 400 people in its three production departments - Rotor, I Stator, and Coil Winding. These include 60 inspectors and testers, who report to the respective shop foremen; they in turn report to a General Foreman 2. The Quality Control Department consists of a Chief and one other QC Engineer one Process Control Engineer, one Technician, three Quality Auditors and one Stenographer. The main jobs of this department have been to provide interpretation of engineering specifications, to follow special engineering tests tests on incoming material for compliance to specifications, and to audit the outgoing product quality. It has taken no active part in evaluating designs methods, processes, product specifications or tolerances Nor has it made any extensive studies of production quality problems 3. Product Engineering issues product, test, and inspection specifications and Manufacturing Planning does the design, development and procurement of inspection and test equipment Recently, QC has been given the assignment for determining the method to be used in inspection and test (I&T;) operations. Most of the I&T; planning has been directed more at after-the-fact failure correction than at defect prevention 4. Inspection manpower is largely concentrated in final inspection (in each production department, where 100% of dimensional and visible characteristics is done One inspector handles incoming material inspection, most of which is of raw material, such as strip steel, copper wire shaft stock, etc. Approximately 5% of incoming shipments do not meet specifications. The Rotor and Stator Core Departments each have a roving inspector who checks samples taken from machines. The record of rejects are on a report sent daily to the QC Engineer They are also supposed to notify the foreman whenever defects are found, but have grown lax about this, defending: it on the grounds that 'you can never find the foreman 'they never do anything about it anyway etc

Explanation / Answer

Quality cost is the extra cost incurred that wouldn’t have happened if things were done with optimum quality. The main objective of reducing quality is to identify and then track areas for improvement, so action can take place and the defects can be improved. One way is to put the money into prevention which will automatically reduce the overall cost. The efforts should not focus on not doing the wrong thing but it should focus on doing the right things to design products and services to exceed customer expectations. Often scrap and rework is one of the highest areas of cost of quality. So focus more on scrap and rework. Often scrap and rework is one of the highest areas of cost of quality.

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