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Problem Increasing Defect

PROBLEM NON-PROBLEM
WHAT
Santa Clause Figures Flowers & Ornaments, Angels
Defect: Bubbles

Cratering

WHERE
Drying Room (Warehouse 2) Inspection, Sanding, Prep
Defect: Bubbles
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WHEN
June 24 Before June 24

HOW MUCH
Object: 20-25% defect 2% defect

Defect: Increasing Decreasing

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ANALYSIS DIFFERENCE CHANGE

Employees 60 additional - production and painting, resistance from old line

employees

Superivision/Foreman Stricter - lessen rework

Profit Sharing Yes

Raw Materials (ex. new paint) New paint was introduced in Line B.

Ventilation improved for better working condition

Lights Greater Illumination

Work Process in ALL Warehouse Improved output but resistance encountered

(especially packaging)
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Rainy Season Usually August but started already

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DATE TIME POSSIBLE CAUSE

March Lack of training of new employees,

low morale, sabotage from
disgruntled employee
Lack of competency, Stricter QA =
rejecting even acceptable output

Last Week Procedure bypass to meet target

output

Few Days Ago mismatch paint

3 Weeks Ago (Today is June 28) Ineffective ventilation system

Wrong specs of light fixtures

Mismatched Capacity;
Oversimplification
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Visayas and Midanao starting June Too much humidity

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FURTHER
ASSUMPTION PASS/FAIL
VALIDATION

FAIL

FAIL

FAIL

Paint might not be Line Testing Pass

compatible with the
Santa Clause design;
unknown drying time of
the new paint material

Change in Line B Measure airflow per Fail

Only? Airflow causes Line
bubbles, brings in dust -
particles that causes the
bubbles

Change in Line B Test Heat Generated by Fail

only?; May have lights per Line
affected temperature
that causes the bubbles

Might have resulted to Compare drying time Fail

faster drying caused before and after process
bubbles change
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in the drying area due How will you change Fail

to cooler temparature your process/how will
your warehouse system
to adjust