PROJECT RISK AND QUALITY MANAGEMENT

Managing Quality
Eastern Power, Inc.

Prepared by,
300624401

17th February, 2011

Outline for Roger Jackson’s report:
Roger Jackson, the consultant of Eastern Power, is supposed to look at the current problems
with rejected products found during the manufacturing operations of wire windings. He will
look after each process to find out the reasons for the defects. After all research, he will give
justification for the situation and recommendations to improve the current scenario. The report
will include all necessary charts, such as –
 Bar chart – to show the flow of defects in all machines
 Pareto chart – to compare the defect causes as per cumulative percentage.

Necessary data calculation for defects will be produced on the excel spread sheet to show the
results. The recommendation will include the point which can direct towards the improvement,
but it will not include the technical recommendation. This recommendation will help in making
the clear decisions about the technical solutions, which will be decided by technology
department.
80 76

70
62
60
Bad Wind
50 Twisted Wire Jackson’s
Broken Leads
40
Abraded Wire
30 Wrong Core
Wrong Wire
20 Failed Electrical Test

10
0 0 2 1 1
0
defect

justification and recommendation:

After looking at all the data, gathered from different department, it seems that major defects in
winding wires include abraded wire, broken leads and wires which failed the electrical test. As
per the following bar charts, winder 3 generates the maximum defects of abraded wire and
produces wires which fail the electrical test.

Bar Chart showing defects due to Winder 3

Winder 1 is generating wires with broken leads. The defects of abraded wire and wire which
failed the electrical test are lesser than winder 3.
80

70
62
60
Bad Wind
50 Twisted Wire
Broken Leads
40
Abraded Wire
30 Wrong Core
Wrong Wire
20 Failed Electrical Test

10 5
3 3 1 2 1
0
defect
Bar Chart showing defects due to Winder 1

On the other hand, winder 2 is generating fewer defects in compare to other two winders.
 80

70

60
Bad Wind
50 Twisted Wire
Broken Leads
40
Abraded Wire
Wrong Core
30
Wrong Wire
19 Failed Electrical Test
20

10 7 5
4 2 2 3
0
defect
Bar Chart showing defects due to Winder 2

As a recommendation, defects from winder 1 and 3 should be taken into consideration

immediately.

As per the Pareto chart, almost 80% from the 100% defects are abraded wire, wire which failed
the electronic test and broken beads.
As a recommendation, the solutions for these defects should be found first.
90 120
80
100
70
60 80
50
60
40
30 40 No. of Defects
20 Cumulative Percent
20
10
0 0
s t
ire ad es ire in
d ire re
W Le la T W W W Co
de
d en tri
c
on
g d d ng
ra ok c r Ba iste ro
Ab Br Ele W Tw W
d
ile
Fa

Pareto Chart
As per the current situation, packaging personnel are inspecting their own work and making
corrections on the spot. Quality control inspects these wires before packaging and still too
many windings are found to be defective which require reworking before packaging. To deal
with this, quality control should be reassessed and improved. Additional corrections in quality
assurance plan can also improve the quality of product and this will reduce the number of
defects.

(Excel sheet containing all the necessary calculation is attached with this report.)