Week 2_ Ejeh Udoka_ Quality Control
Problem Statement;
QC weekly report from the Fabrication shop records increased weld rejection rates within the last month.
Possible Causes;
-individual welders performance making the welds,
-use of damp or contaminated electrodes,
-use of un- calibrated equipment.
Action Plan;
-isolate the weld defect types,
-check trend if any
- establish the exact cause of the rejects.
Possible Solutions / Alternates;
-identify and withdraw the welder(s) and subject to retraining / requalification.
-ensure electrodes conditions are used as manufacturers recommended conditions,
-strengthen the process control measures,
-improve inspection and QC supervision / monitoring,
-train shop floor personnel.
Possible Outcome; Coordinated effort will improve the metrics.
Acceptance Criteria; developed quality metrics matched with project/ contract requirements.
Compare and analyze the alternatives (solutions); each of the alternatives as listed will not work in isolation if implemented, instead an integrated process approach is recommended to achieve the desired result.
And for this to be effective, personnel must be adequately trained, process control procedures enforced and a motivated work force.
References
GP 29-03-06 Onshore Structural Welding and Inspection
GP290309 Offshore Structural welding and Inspection
GP 20-01-04 Upstream Project Quality Assurance - General Requirements
Client specifications and control procedures.
Hi Ejeh,
ReplyDeleteSame comment as W3 posting......
Step 1- GREAT problem/opportunity statement- definitely on the right track....
Step 2- Develop feasible alternatives... How did you arrive at the ones you did? How do you know you didn't miss any? Where is your Root Cause Analysis?
Step 3- Develop benefit:cost, cash flow or other financial assessment of the alternatives. Which of the alternatives will give you the best results for the least cost? See Engineering Economy or Skills and Knowledge for the various cost comparison tools.
Step 4- Selection of the criteria- What are the rejection rates right now? What are the acceptable rejection rates? How many hours retraining do you expect to provide each welder? What about testing and calibrating the equipment? What tools/techniques did you use from the material I provided you that can help you QUALITATIVELY or QUANTITATIVELY develop solid, measurable metrics? Did you ever prepare any Pareto Charts (Memory Jogger page 122) How do you know the frequency of the problems relative to one another?
Step 5- What tools/techniques did you use to compare the alternatives before making a decision which one/ones to implement? Looks to me from what you posted that you are using the "trial and error" method right? Try something, see if it works and if not, then try something else?" Is that good management? Is that the way to move Nigeria from a developing nation to a developed nation?
Step 6 Selection of the preferred alternative. I see you made a decision, but I see nothing to support or justify HOW that decision was made. Guessing? Prayer? ????? What I am looking for and what I am hoping to develop in this course are people who are capable of analyzing problems using the scientific method, then arrive at solutions to problems that are based on sound financial and cost data. What I don't want are people who "fly by the seat of their pants"..... You cannot run a successful business that way for long....
Step 7- Follow up and monitoring. How about looking at Pareto Charts or better yet, how about Process Control Charts on page 53 of your Memory Jogger or Process Capability Analysis, on page 173? Did you use any of these tested and proven tools in your decision making process? If not, why not?
Again, I will accept this weeks posting, but for the future posting, I will be expecting to see evidence that you are actually using the tools and techniques I am trying to help you to learn. If you do that, I am confident you will get better, more consistent results.
Keep in mind- "If you always do what you have always done, you will always get what you have always gotten". Change starts with YOU.
BR,
Dr. PDG, Jakarta