Posted: November 29th, 2022

OPMT 1106: Quality Management Fundamentals Assignment

OPMT 1106: Quality Management Fundamentals Assignment #2
– due Nov 15, 2022 (by 6:30pm class time)
Submit files via Learning Hub in .pdf or word preferred. Late submissions will be
deducted marks.
Application of Knowledge
Congratulations! You have just been hired by a company as their new Quality Manager. They are a large
manufacturer of parts for the aerospace industry. The boss sits you down on the first day and indicates
that “quality seems to be all over the place.” She asks you to analyze the various parts of the process and
provide some details and recommendations. She says: “You’ve got your job cut out for you…good luck!”
She gives you the following data for # of bad parts produced per day for the last month and the bad parts
produced per machine in the last month:

As a newly trained Quality Assurance Manager, you know that proper data analysis will be the first step.
You go visit Ray, the Production Supervisor, for an overview of the process. He says: “Well, we get the
raw material from our suppliers. As it comes in, we do an inspection and if product is good, it goes to the
inventory area. However, if it’s bad it goes into our quarantine area to go back to the supplier. We get an
order to make new parts, so we will pull the stock from inventory to one of our 5 machines. The lead
operator sets up the machine and then needs to get authorization the setup is ok. If it’s ok, then we will
run the order. If it’s not, they redo it again until it is. Once the order is running, they will inspect 1 in
every 10 pieces. They assess this sample to make sure its ok to keep running. If the inspection is bad,
they go back to working on the setup. Once the order is done, it’s sent to shipping. They wrap the order
and send it to the customer. Pretty easy, really.”
You also find out they hired a consultant before you but she left before she was able to properly analyze
the data and determine Upper and Lower control limits. However, the company, based on feedback from
their customers, wants to see a goal of zero defects to a maximum of 10 per day.
Day Defects Day Defects Day Defects
1 17 11 28 21 27
2 15 12 15 22 22
3 29 13 26 23 16
4 20 14 14 24 17
5 22 15 22 25 23
6 18 16 18 26 20
7 22 17 22 27 24
8 19 18 14 28 16
9 16 19 16 29 22
10 23 20 22 30 19
Machine Defects per month
1 30
2 103
3 136
4 250
5 85
As you continue your investigation, you find out there has been a brainstorming session before you
arrived so they could try to understand the recent quality issues. They put together the ideas in the
minutes but haven’t done any other analysis with them so far. They are:
1. Our raw stock over the last few months seems to be getting worse
2. We got a lot of new operators over the last few months who’ve been pushed to the floor quickly
3. The dial on Machine No 4 is worn out and very hard to read
4. We’ve been using the same specifications since I started here 10 years ago
5. I really don’t know how they expect us to check the samples when half the lights are burnt out
above the machine…I can’t see anything!
6. I don’t know what the issue is – I follow the standard procedures, same as John on Machine 1.
Not my fault the other guys do things their own way.
7. I don’t know how they expect the glue to hold when it’s so cold in the warehouse
8. Machine No 3 has some very old parts that are loose
9. Bill is the only one who seems to know how to do the proper checks and he’s off on sick leave
10. I’m told to do a different type of quality check by the designers, the supervisor and even the boss!
11. When setting up our dies, the wood used on the dies is brittle and can crack causing issues
12. I’ve tried to check the depth of the finished goods, but the tape measures are all different
Digging further, you determine that the organization has set up an AQL for their inspections as per below:
Major Issue – AQL of 0.1 – with a lot size of 25,000 pieces and using General Level 2
Medium Issue – AQL of 0.65 – with a lot size of 25,000 pieces and using General Level 2
Minor Issue – AQL of 6.5 – with a lot size of 25,000 pieces and using General Level 2
Finally, you are given the following quality costs for the last year:
Qualifications of Supplier Products $675
Laboratory Support $575
Process Control measurements $1960
Field Performance Assessment $2555
Depreciation Allowance $2354
Review of Test and Inspection Data $265
Measurement Equipment $585
Inspection and Test Materials $554
Purchasing Appraisal Costs $155
Maintenance & Calibration labor $4558
Retrofit Costs $360
Warranty Claims $39,890
Recall Costs $28,000
Disposition Costs $250
Troubleshooting costs $38,675
Scrap Costs $22,000
Material Review and CAR Costs $4,560
Supplier Reviews $1,200
Operator Quality Education $50
Contract Review $225
Quality Administration $550
Now that you have everything, it’s time to get to work!
For this assignment, you must do the following:
 Analyze the quality costs, separate each one into each cost type and determine % in
each cost type. Do not round up or down – show to two decimal points (i.e.:
00.00%).
 Create an Ishikawa Diagram of the brainstorm session
 Create a detailed flowchart of the process
 Create a control chart of the appropriate data – you must show your calculations and
do not round up or down – show to two decimal points (i.e.: 00.00).
 Create a pareto chart of the appropriate data
 Calculate what the AQL information is
 Finally, on minimum two full pages to maximum three full pages (font size 12,
single spaced), provide a summary of your observations and recommendations based
on each of the data metrics you have analyzed (except the AQL data). This page
count does not include your graphs!
 No bibliography is required
Grading Criteria
 Quality Cost Analysis 10%
 Ishikawa Diagram 10%
 Flowchart of Process 10%
 Control Chart 10%
 Pareto chart 10%
 AQL Calculation
 Observations & Recommendations
10%
40%
Total Grade 100%

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