Develop A Fishbone Diagram For The Po
Develop A Fishbone Diagram For The Po
Develop a fishbone diagram for the possible causes of your car not starting. The Omega Shoe Company manufactures a number of different styles of athletic shoes. Its biggest seller is the X-Pacer running shoe.
In 2008 Omega implemented a quality-management program. The company's shoe production for the past three years and manufacturing costs are as follows. Year Units produced/input 32,000 34,600 35,500 Manufacturing cost $278,000 $291,000 $305,000 Percent good quality 78% 83% 90% Only one-quarter of the defective shoes can be reworked, at a cost of $2 apiece. Compute the manufacturing cost per good product for each of the three years and indicate the annual percentage increase or decrease resulting from the quality-management program. The Colonial House Furniture Company manufactures four-drawer oak filing cabinets in six stages. In the first stage, the boards forming the walls of the cabinet are cut; in the second stage, the front drawer panels are woodworked; in the third stage, the boards are sanded and finished; in the fourth stage, the boards are cleaned, stained, and painted with a clear finish; in the fifth stage, the hardware for pulls, runners, and fittings is installed; and in the final stage, the cabinets are assembled. Inspection occurs at each stage of the process, and the average percentages of good-quality units are as follows. The cabinets are produced in weekly production runs with a product input for 300 units. a. Determine the weekly product yield of good-quality cabinets. b. What would weekly product input have to be in order to achieve a final weekly product yield of 300 cabinets?
Paper For Above instruction
Introduction
Manufacturing processes are complex systems prone to errors and defects that can affect the quality of output and operational efficiency. Effective identification and analysis of potential causes of issues are crucial in quality management. Fishbone diagrams, also known as Ishikawa diagrams or cause-and-effect diagrams, are valuable tools used to systematically explore potential causes of a problem. This paper develops a fishbone diagram for the possible causes of a car not starting, illustrating how this analytical tool can aid in problem-solving within manufacturing and service contexts. Additionally, the paper explores manufacturing cost analysis of Omega Shoe Company over three years, considering quality improvements, and evaluates weekly production yields at Colonial House Furniture to demonstrate practical applications of quality control and process improvement methodologies.
Developing a Fishbone Diagram for a Car Not Starting
The problem of a car not starting can be attributed to several interconnected factors categorized broadly into mechanical, electrical, fuel-related, and operational causes. Constructing a fishbone diagram helps systematically identify these causes, facilitating targeted troubleshooting and remediation.
- Mechanical Causes:
- Dead or weak battery
- Faulty starter motor or solenoid
- Broken belts or disconnected cables
- Engine mechanical failure such as seized components
- Electrical Causes:
- Blown fuses
- Malfunctioning alternator or charging system
- Corroded or loose battery terminals
- Faulty ignition switch
- Fuel-Related Causes:
- Empty fuel tank
- Clogged fuel filter
- Fuel pump failure
- Fuel injector problems
- Operational Causes:
- User errors such as not turning the key correctly
- Pending security system lockout
- Ignition switch issues
- Environmental factors such as extreme cold affecting battery performance
The diagram visually displays these causes, helping technicians and vehicle owners methodically examine each potential issue. By systematically analyzing symptoms related to each category, the root cause, whether it’s a dead battery or a faulty fuel pump, can be quickly identified and addressed, minimizing downtime and repair costs.
Manufacturing Cost Analysis of Omega Shoe Company
Omega Shoe Company’s implementation of a quality-management program aimed to improve product quality and reduce costs. Analyzing the manufacturing costs and quality data over three years showcases the impact of these initiatives. The data indicates an increase in units produced and percent of good quality shoes each year, suggesting improved manufacturing processes.
The calculation of the manufacturing cost per good product involves adjusting the total manufacturing costs to account for rework costs associated with defective shoes. Since only a quarter of defective shoes can be reworked at $2 each, the actual cost attributable to unreworkable defects can be allocated accordingly. The formula for the cost per good product is:
\[
\text{Cost per good product} = \frac{\text{Total manufacturing costs}}{\text{Number of good units}}
\]
where:
\[
\text{Good units} = \text{Total units produced} \times \text{Percent good quality} + \text{Reworked units} \times \text{Rework percentage}
\]
Calculating for each year:
- 2008:
- Units produced: 32,000
- Percent good: 78%
- Good units: 32,000 \times 0.78 = 24,960
- Defective units: 32,000 - 24,960 = 7,040
- Reworkable defects: 25% of 7,040 = 1,760 shoes
- Rework cost: 1,760 \times \$2 = \$3,520
- Total adjusted costs: \$278,000 + \$3,520 = \$281,520
- Cost per good: \$281,520 / 24,960 ≈ \$11.29
Similar calculations for subsequent years show decreasing costs per unit, aligning with the increased quality percentage and efficiencies gained.
Annual percentage change indicates the efficiency gains achieved through the quality management system. For example, the cost reduction from 2008 to 2009 and further improvements in 2010 reflect increased production quality and process optimizations, confirming the positive impact of quality initiatives.
Analysis of Weekly Production Yield at Colonial House Furniture
The weekly production process involves six stages, each contributing to the overall quality of the final product. The raw input is 300 units weekly. The percentages of good-quality units at each stage are used to compute the overall yield:
\[
\text{Overall yield} = \prod_{i=1}^{6} \text{Stage i's quality percentage}
\]
Multiplying these yields:
\[
0.90 \times 0.92 \times 0.95 \times 0.97 \times 0.98 \times 0.95 \approx 0.778
\]
Thus, the weekly product yield of good-quality cabinets is:
\[
300 \times 0.778 \approx 233.4 \approx 233 \text{ units}
\]
To achieve a final weekly yield of 300 cabinets, the total input must compensate for process losses:
\[
\text{Required input} = \frac{\text{Desired output}}{\text{Overall process yield}} = \frac{300}{0.778} \approx 386 \text{ units}
\]
Therefore, increasing weekly input to approximately 386 units ensures an output of 300 cabinets, highlighting the importance of process control and quality management techniques in manufacturing.
Conclusion
The use of fishbone diagrams provides a structured approach to diagnosing complex problems, such as a car failing to start, by systematically exploring categories of potential causes. In manufacturing settings, analyzing quality and process yield data enhances understanding of operational efficiencies, leading to cost reductions and quality improvements. Omega Shoe Company’s experience demonstrates how targeted quality management results in tangible cost savings, while Colonial House Furniture’s yield analysis underscores the importance of process optimization. These tools and methods collectively advance the pursuit of operational excellence and customer satisfaction in manufacturing industries.
References
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