February 28, 2013
As the newly hired director of quality, the first step in identifying the quality issues within the plan t is to understand the basic root cause of the problem. The general manager, Morgenthal, has already mentioned lack of quality attitude in the plant and the on-going problems within the plant. These are some of the problems and root causes that are plaguing the quality department.
Newly hired employees/ employees who are being transferred to other production departments are not properly trained, on the job training is provided by the front-line supervisor during the run operation, any defects or rejects material was not disclosed to the operator during the shift and the operator of the filling equipment is not suitable for the job because of lack of knowledge and proper training. Personnel had stated that the operator had just be transferred in without any formal training and the on-the-job training was by an unqualified person shows proper training is not viewed as a prerequisite to start a job which leads to unqualified people performing processes. The operator was not around when the Quality Control manager did the testing demonstrates inspections that are after the fact with out in-process controls or feedback loops. Plant Maintenance
The equipment used for the Greasex was not originally designed for this type of lower viscosity; special filing heads were created in order to run the product on the machine. The last six months the maintenance department has completed 12 work orders for repairs and adjustments to the machine, no preventive maintenance has been scheduled for this machine though it has been down 15% of its actual run time. This shows a lack of product tractability, lack of quality maintenance records of the equipment so improvements can be made. Purchasing
The plastic nozzles were a rush order, the heads had burrs on the inside rim...