1. Discuss your plants quality levels, ability to deliver and overall cost of (poor) quality.

What are
the opportunities that you can pursue? What is the potential cost savings to be realized?
Solution:
Based on the data collected and analyzed the plant is currently producing almost 61% defective
parts. Based on the right first time data the percent target achieved for each shit is only 0.36 or
36%. The plant is also not meeting its target based on the average cycle time which is currently
2.93 seconds per unit. The plant is unable to deliver the product target of 1000 units per shift. The
overall cost of poor quality is 183,000,000 dollars.
Based on the data following are the improvement opportunities:
 Reduction in % defectives which is currently a very high number at 61%.
 The right first time and the target achieved for shift can be improved which is currently only
0.36.
 The current average cycle time is 2.93 which can be reduced to 2.5 seconds the required Takt
time.
Data indicates that by reducing the defects the cost of poor quality that can be decreased is
183,000,000 dollars.
2. What were some of the difficulties with data collection that you observed? Are there any
process improvement opportunities that jump out of you from your “Go see” process walk /
baseline analysis?
Solution:
Difficulties observed during data analysis are:
 Unviability of the past data.
 Catapult reloading time is greater than what it should be.

Process improvement opportunities arising from base line data are:

 Improving the Catapults not meeting the specifications target which is 100 + 2.
 Training the operators who are all have less than 1 year experience currently.
 Projectile cups manufacturing machines are old and can be improved.
 Proper planning before taking the orders is required.

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3. Catapult QC report.

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