Greasex Case Study

In the high-technology sector, the Greasex line is specialized in manufacturing solvents packed in cans for degreasing. Nonetheless, the company had experienced some trouble with the new filling equipment. The main problem was the presence of high-pressure beyond the required upper specified limit in some second shift cans. However, these problems as identified from the case study are related to several areas. They include personnel such as the newly assigned operator from a different department. He lacked formal training and was also negligent as he was absent from his position of operation during the process. Moreover, Mac Evans; the line supervisor, after picking and tagging the cases as “hold”, went on his duties and did not supervise their progress. Although vetted by hand by Wayne Simmons, the first-line supervisor, they could still be of low quality and pose safety threats to the customers. In addition, the machinery used was not initially designed to handle the process involving lower viscosity of Greasex, lacked preventive maintenance schedule. The appropriate equipment, which is the special filling head for the process, had been poorly and haphazardly adjusted. Materials used in production such as plastic nozzle can heads were designed on a rush order by a vendor and, therefore, had slight burrs on the inside rims causing fitting problems. They had to be forced on by increased pressure application at the filling head. Hamler; the quality control manager, on the other hand, does not check with maintenance to ensure adjustment of filling machine. With regards to the production plan, although the rejected Greasex cans were vetted thus delivered in time, Simmons was avoiding delays on the shipment schedule. He was supposed to send them to the rework area to ensure quality standards of productions. Measurement on the possible outcome of the process on the product design and packaging was not accurately done. This is because the contoured- can acted as a carrier creating suction from a high-pressure filling head. The management generally failed on its part as it hastily introduced Greasex to beat competition, therefore, producing a product with 50% standard rates. General Steps to be taken by Hank to set up a Continuous Improvement Program for the Company The continuous improvement program for the company entails improvement of quality. The information provided by Morgantal, the general manager, concerning the lack of quality attitude would play an important role in his efforts. For solutions to be found, Hank, the new director of quality assurance needs to brainstorm with other managers and supervisors. He will have to use the Six-Sigma project method and Design, Measure Analyze, Improve and Control the processes of implementation. In general, it will put a stop to the downward quality-productivity-turnover trend and reduce the cost in terms of money spent. To achieve this, he has to start by talking to the staff in the production unit