Managing Quality: Nakamika Electric Case Study Nakamika Electrical Components, Inc. is a small-size San Andreas-based ma

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Managing Quality: Nakamika Electric Case Study Nakamika Electrical Components, Inc. is a small-size San Andreas-based manufacturer of wire windings used in electric motors. Chan Stanley, VP of operations, has experienced an increasing problem with rejected products found during the manufacturing operation. "I'm not sure where to begin," admitted Chan at the weekly meeting with his boss. "Rejects in the Winding Department have been killing us the past two months. Nobody in operations has any idea why. I have just brought in a consultant, Arthel Watson, to take a look at the situation and make recommendations about how we can find out what is going on. I didn't ask Arthel to make technical recommendations - just see if he can point us in the direction of our problem." Watson's first stop later that day was the production floor. His discussions with the production supervisors in the Winding Department indicated that they had no real grasp of what the problem was or what to do to correct it. A tour of the winding operation indicated that there were three machines that wound wire onto plastic cores to produce the primary and secondary electric motor windings. After inspection by quality control (QC), these windings then went to the Packaging Department. Packaging personnel, Watson found, inspect their own work and make corrections on the spot. It is apparent to Watson that the problem lies in that too many windings

ing operation indicated that there were three machines that wound wire onto plastic cores to produce the primary and secondary electric motor windings. After inspection by quality control (QC), these windings then went to the Packaging Department. Packaging personnel, Watson found, inspect their own work and make corrections on the spot. It is apparent to Watson that the problem lies in that too many windings are found to be defective and require reworking before they can be packaged, rather than in the Packaging Dept. Watson's next stop was the Quality Control Department, where he obtained the records for the past month's Winding Department rejects (see table below). ASSIGNMENT DIRECTIONS AND QUESTIONS: - 1. Prepare Arthel Watson's recommendation, with justification, on one page. (Write it up as a memo/letter - be concise - one page of text with your recommendation and information backing up your conclusion) 2. What charts, graphs, computer printouts, and so forth might be included in the report to support your recommendation?

- memo/letter be concise one page of text with your recommendation and information backing up your conclusion) 2. What charts, graphs, computer printouts, and so forth might be included in the report to support your recommendation? (You don't have to prepare all of the charts, graphs, etc. - just provide a description of what you would include as addenda to your letter). 3. Prepare the detail necessary to supplement Watson's recommendation and justification so that Chan Stanley will understand how Watson arrived at his recommendations, and be able to present them to his management so they can correct the issue. . Clarification: • I do want you to prepare some kind of condensed data presentation. • One table and one graph at least - whatever you think will do the best job of conveying your findings quickly to management. Include it as an addendum to your memo/letter - it does not count toward your one page of material. .

• Be aware that you may have to manipulate the data (normalize, average, etc.) to fully capture what is going on (and before you put it in a table, chart, etc.). Note: Assume each defective unit was rejected because of one single defect. I

Number of Rejected Units per Cause Bad Wire Winder Unit Twisted Wire Broken Leads Abraded Wire Date 1 Wrong Core No. Inspected 100 100 Wrong Wire Failed Electrical Test 0 1 4 0 0 1 0 0 2 0 0 1 1 0 3 0 100 100 3 1 0 1 1 4 0 0 2 0 1 3 0 0 0 0 1 2 0 0 1 0 0 2 0 3 1 2 0 0 1 0 0 3 100 100 100 100 100 0 0 0 1 2 0 0 0 0 0 0 0 0 A WNAWNAWNE 0 0 3 1 3 0 0 5 0 0 4 100 3 0 0 0 0 0 0 100 1 T2 3 0 0 1 0 OO OO WAO 0 0 2 4 0 0 1 0 5 1 5 1 0 100 100 100 100 0 0 0 2 OON 0 0 1 3 0 0 0 0 2 0 0 3

TUU 3 0 0 2 1 Ол 5 1. e 5 0 0 o 0 0 0 0 2 3 1 0 0 0 0 3 0 8 0 0 1 2 0 0 0 0 0 0 3 3 1 0 0 9 2 ololololololo oo 0 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 2 0 o 0 0 0 0 0 1 2 3 1 0 0 0 0 4 0 0 10 4 0 5 0 OP WOO DoouoonloonOouc O ON 2 0 0 0 1 0 0 4 NOONNONOO AO 0-OloWOON 0 0 0 ω Ν Η ω Ν Η ω Ν Η ω Ν Η ω Ν Η ωINI 3 1 0 4 3 0 11 o 0 0 0 2 0 0 0 0 1 0 0 2 0 O 2 0 1 12 100 1 0 0 0 0 100 2 2 0 0 4 0 0 0 0 3 2 0 0 0 15 1 2 0 0 0 0 0 100 100 100 100 2 0 0 0 0 0 0 3 0 0 7 0 0

12 a Paragraph 2 100 0 0 0 0 O 100 3 0 2 Styles O 7 0 0 0 0 0 16 1 6 0 0 0 100 100 100 0 0 0 0 OOO 0 0 0 WN 2 3 NIO 0 0 2 0 3 0

Number of Rejected Units per Cause Bad Wire Winder Unit Twisted Wire Broken Leads No. Inspected 100 Abraded Wrong Wire Core Wrong Wire Failed Electrical Test Date 17 1 1 1 1 1 0 1 NE 2 0 5 0 0 2 100 100 100 3 0 0 5 0 3 0 0 18 1 2. in Oo 0 0 0 0 100 2 0 0 3 0 0 3 100 3 0 6 0 0 0 0 19 2 2 0 WNAWNAWNA 0 0 2 0 o 100 100 100 100 100 3 O NOONOO Woowooo 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 3 0 4 3 0 22 1 4 0 0 0 2 O 0 2 0 0 3 0 3 3 0 0 100 100 Olomon 23 1 4 0 0 0 0 0 100 100 2 WOO wN 2 3 1 2 0 0 0 0 0 3

0 0 2 0 100 3 0 3 1 2 0 0 0 0 24 1 2 0 100 100 0 0 0 0 0 0 2 0 0 1 1 0 0 0 100 3 0 3 0 0 3 0 0 25 100 1 6 0 0 0 0 0 0 2 0 0 0 1 WN 0 100 100 100 1 0 3 o 4 3 1 0 0 0 OOO 26 1 0 0 o 0 100 2 0 0 1 0 0 0 1 100 3 0 5 0 0 4 0 0 29 100 1 2 0 0 0 0 0 100 N 0 0 4 0 0 0 0 0 0 CARD COD 100 3 0 4 0 0 30 0 1 0 2 0 0 0 0 0 100 100 100 0 1 2 0 1 0 0 0 0 1 3 5 0 0 4 0 0