Case Study Assignments


Case Study Assignments

Want process mapping chart with advantages and disadvantages in two different flow charts. ABC Company is a major manufacturer in windows and doors industry. The company receives raw material and components from suppliers and assembles door handles for its customer so it can be assembled in windows and doors.

The company has three different layer of inspections that allow them to ensure good quality of products are being shipped to customers.

Incoming inspection:

Company receives components and raw material from different suppliers and before they receive them in the company the shipper and receiver conducts the following checks

  • Ensures the quantity is correct as per the packing slip
  • Ensure the material certification is available
  • Ensures that products are not damaged

Upon any nonconformance on above items, let the driver know and return the products to the supplier and if can’t unload them and place them on hold status so it can be returned at a later time.

If all the above items were OK, then shipper receiver notifies QA so the quality inspector can start inspection the products.

Quality inspector inspects the products as per the incoming inspection instruction for that particular product and conducts the inspection. Upon any nonconformance, the product will be placed on Hold and QA notifies the supplier quality engineer to contact the supplier so the product can be returned to them. If everything was OK, then accepts the product and notify the receiver so he/she can receive the product and enter the quantity into the inventory database.

In Process Inspection:

Machine operators inspect the first part that is being produced as per the written instruction that is provided to them by Quality Engineers and if everything is OK, then take the sample to Quality Lab so QA inspectors can do additional inspection on the part. If operators don’t accept the parts they need to notify the setup operators so they can fix the issues. Operator do not take any products to the lab if they don’t pass their initial inspection.

QA inspector inspects the product as per the inspection instruction that is provided to them and release the product if everything is OK so operators can start the production. Operators cannot start the production if quality does not OK the product. If the product is not OK, then the QA inspector rejects the part and operators need to notify setup operator so they can fix the issue. If the issue needs maintenance to resolve the issue, then QA inspector issues a work order to maintenance so they can start fixing the issue. This will continue until a good product is being delivered to quality.

In addition to the First off inspection, QA inspector checks 3 pieces every 2 hours in order to ensure products are within the specification and follow the above procedure if the parts found to be not OK 

Final Inspection:

Upon completing the order, production supervisor orders to transfer all products to the shipping quarantine area and asks QA inspector to review the products and release them to shipping if everything is OK.

QA inspector randomly selects some parts from different containers and conduct inspection as per the written instruction that has been provided to them. If all aspects are OK then products being released to shipping and QA inspector updates the inventory so shipping department be able to ship the products.

If the parts are not OK, QA inspector will place the product on Hold so it can be reviewed more in detail. Quality Engineer regularly reviews on hold products and makes a disposition whether the product can be used as is, to be scrapped, or reworked and notifies QA inspector on the final decision. QA inspector updates the status of the product in the inventory according to QE instruction and will notify production on the final disposition of the product. Production supervisor follows the instruction by QE.

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