Delta Plastics Case Jose De Costa, Director of Manufacturing at Delta Plastics,

Question

Delta Plastics Case

Jose De Costa, Director of Manufacturing at Delta Plastics, sat at his desk looking at the latest production quality report, showing the number and type of product defects per week (see the quality report in Delta Plastics, Inc. Case A, Chapter 5). He was faced with the task of evaluating production quality for products made with two different materials. One of the materials was new and called “super plastic” due to its ability to sustain large temperature changes. The other material was the standard plastic that had been successfully used by Delta for many years. The company had started producing products with the new “super plastic” material only a month earlier. Jose suspected that the new material could result in more defects during the production process than the standard material they had been using. Jose was opposed to starting production until R&D had fully completed testing and refining the new material. However, the CEO of Delta ordered production despite objections from manufacturing and R&D. Jose carefully looked at the report in front of him and prepared to analyze the results.

Case Question

Are both materials equally subject to the defects?

Explanation / Answer

Yes, both the plastics (materials) are equally prone to defects. Defects are mostly due to a flaw in the production process and not the material. The standard material that the company had been using for years has less defects due to the fact that they are used to the material handling involved in the process. However, if proper R&D and testing is done for the new material and an accurate training process is developed for material handling of the new plastic, it will also result in less defects.

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