Hank Kolb QA case study PDF

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Assignment report _________________________________ Quality Management Systems MBA Quality Management

• Participants List:

Name

WILP ID

Shivendra Kumar Singh

2019hb74524

Hemant Shirsale

2019hb74503

Venkataswamy Y

2019hb74509

K Guruvayurappan Vivek

2019hb74533

R Sri Ganesh

2019hb74507

Assignment Topic: Hank Kolb, Director Quality Assurance (QA) Case

Q 1.

Write an appropriate Quality Policy for the Greasex Line. Purpose: To manage activities in accordance with the framework of the policy and to achieve quality assurance and customer satisfaction.

• •

It is the responsibility of all department managers to help define, implement and maintain the procedures required by the quality policy and ensure that processes confirm to these requirements. The system is maintained and continually improved through the use of quality policy, quality objectives, internal and external audit results, analysis of data, corrective and preventive action and periodic management reviews needs to be done. Quality Policy:

• • •

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Top management ensures that the quality policy is appropriate to the purpose of the organisation and it is communicated to all employees and training the new employees too. It is the policy of the Greasex Line to provide the customer with goods and services to the agreed requirement in accordance with the details and price. The Directors, Management and Staff are responsible for Quality Control through the Quality Management System seeking improvement by constant review, with suppliers and sub-contractors being encouraged to co-operate. The Company is committed to achieving customer satisfaction by the use of quality procedures which will be operated to meet or exceed the requirements of ISO 9001. Strives for zero defects and no waste by constantly looking for opportunities to apply our continuous improvement approach to deliver competitive advantage. Create and nurture people of quality by continuous education and training. Maintain & improve standards of manufacturing. Establish a “Total Quality” framework to continually improve the quality Management System and realise challenging Quality objectives. Record and control the change points at each stage. Prevent defect outflow to next process, and feedback to previous process for enhanced Quality Assurance. Strengthen supply chain by effective traceability system. Continuous Quality Improvement:

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It focuses on identifying sub optimal processes and changing them for improving quality. Benefits of CQI: 1. Error Reduction 2. Increased Adaptability 3. Increased productivity 4. Improved financial strength 5. Improved communications and team work.

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Flow chart furnished of the Greasex line production procedures performed with the aid of using multi-practical crew of maintenance, purchasing, layout engineering, packaging and production. Use Histogram through the years to assess if the defects are going down.

Q 2. Who was the Quality Control Manager? And what did he do with the problem? o Mark Hamler, Hank Kolb’s immediate subordinate was the quality control manager. o He did not take quality seriously and there were some cans found with high pressure that were supposed to be sent to the rework area. But, since the production planning did not want any delay, the cans were manipulated by Wayne Simmons, first line supervisor, by venting them out so that they could be shifted in time. o As he wanted to do more investigations, he talked to the different departments and learned some information. o There were various problems involved from personnel to marketing, but what bothered Kolb the most was the safety issue of the high pressure in the cans. He had no way of knowing how much of a hazard the high pressure was. Although some tests had been done that proved that there was no danger, there were still many questions in his mind such as the reliability of the test or whether or not the same quality problems will end or continue. o Hank Kolb was hired as a director of quality assurance. Before Kolb started his job, he was advised by Morganthal, a general manager, that Greasex manufacturing plant lacks quality attitude and Kolb’s main job is to try to do something about it. Therefore, he is here to put an end to the firm’s downward quality-productivity- turnover spiral.

Q 3. Develop a Fishbone Diagram on the causes of problems on Greasex Line.

Following were the problems on Greasex Line and they were related to➢ Product design ➢ Process design ➢ Marketing ➢ Manufacturing ➢ Quality assurance o Elaborate in tabular format in below

Product design

Process design

Marketing

Manufacturing

Quality assurance

Plastic nozzle head design in rush

Filling machine purchase for another product and used for Greasex

Greasex rushed to market

Filling operator

Accepted poor quality part (i.e., burned nozzle)

Improper supervision No formal training New to machine

Can design without consider production process

Lack of preventing maintenance schedule

Major promotion put pressure on manufacturing

Wayne Simmons

Lack Vendor specification

Inadequate supply of spare part

Consider low quality Greasex better than no Greasex

Removed Hold tags

Increased pressure to compensate for burn on nozzle Process design not in line with product design Inappropriate modification of machine

Vented can manually without pressure gauge

Lack of process control

Low QA importance No respect QA Did not convey sense of urgency i.e quality issue...