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Defect Analysis project – direction needed

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  • #48236

    Bambace
    Participant

    Experts,
    I have just been assigned a new project – need some direction on the approach.  Here is the goal statement:  Can soemone help me with a approach?  Should I process map first, then build a ABC? etc…

    Identify, categorize, and baseline defects across the company value chain. Achieve a X% reduction in critical defects that impact downstream processes and customer satisfaction.

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    #161803

    Chad Taylor
    Participant

    Jessica
    Your statement seems a little broad; can you make it a little more specific to area of concern? Or is this a high level executive project.
    Chad Taylor

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    #161805

    GB
    Participant

    You need to pushback and pare the scope down considerably.   This is not a project, it is likely multiple projects.
    Your Boss needs to realize that this is “World Hunger”.  

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    #161820

    Ronald
    Participant

    Jessica- I agree with the others here.  You have really been charged with two things.  The first is to establish a metrics and reporting system around defects in your processes.  This is more of a business process improvement project that may need some changes to defect reporting, data collection, and analysis.  If you already have a good defect tracking system the baseline should be easy (control charts, paretos, etc.)
    The second part of this (defect reduction) will really depend on what you find in the first part.  You may have several projects focused on specific defects and their root causes.  These improvements in cumulative may help meet the reduction target.  If you try to tackle all the major contributiors in one project you will find issues with timelines and focus.  Therefore your statement is really more of an initative or program in which smaller better scoped project should be identified.
    Good scoping of the projects is key.  Once scoped properly, then it will evident on what to do to move forward (process mapping, process measurements, defect analysis, FMEA’s, DOE’s, etc).

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    #162253

    Ashman
    Member

    I would start by doing a pareto of your defects that are critical to quality (CTQ).  Once this is done you have a starting point,  Some like to use 80/20, I personally like to use 50/4 to narrow the scope.  While using Cpk Calculation will tell you where you are, generally talking with the operators will give you a good start on the Why’s.  Also take a look at the variation in time to complete a task.  Higher variations generally indicate quality issues that the operators are dealing with.  Then proceed with all of the analysis tools available. 

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    #162255

    Confused
    Participant

    50/4?
    I’m comfused

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    #162259

    Ashman
    Member

    80/20 rule is a power curve
    50/4 lies on the same power curve but with tighter focus.

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    #162260

    Confused
    Participant

    Do you have an example? I’m lost
    If i had 100 data points on a pareto scale that has a uniform distribution, what would a 50/4 look like and how would it be interpreted?

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    #162268

    Ashman
    Member

    What this means is that 4% of your issues create 50% of your problems.  Do your pareto, sort from high to low and concentrate on the top 4%.  Very often, especially if you do not have process teams but must go across functional areas, it can be benefical to highly focus.  Reducing your problems from 20% to 4% does this quite well.  Then go back and do it again if time an resources permit.
     
    Steve

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    #162273

    Confused
    Participant

    well wouldn’t that be a 4/50 rule vs. 50/4? sorry, i’m confused

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    #162274

    Brandon
    Participant

    Nice catch, Confused.

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    #162279

    fake accrington alert
    Participant

    If  I’m  the  famous 
     Stan I  would  tell  you  to  do  you  your  own  homewok  which  you are  paid  for and  stop  using  this  fORUM as a  “Spoonfed” port. 
    fake Stan Alert 

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    #162291

    fake accrington alert
    Participant

    Keep it  like  this ,otherwise  you  will  not  be  confused

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    #162292

    fake accrington alert
    Participant

    Jessica
    You  are  lucky  because  your  name  is  Jessica.
    So  every  decent  expert  is  jumping  up  to  do  your  homework  for  you.Imagine  what  will  happen  if  your  name  is  “ATI”?What  kind  of  silly  responses  you  would  receive  from  Stan,Darth,etc.
    Can  I borrow  you  name  for  one  week?

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