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Flyrock Case Study Questions 1 - 3 Tips

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27 views10 pages

Flyrock Case Study Questions 1 - 3 Tips

Uploaded by

Manoj Ram
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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FLYROCK CASE

STUDY
QUESTIONS 1 - 3
BACKGROUND

• You are working for Susan Douglas – VP Quality

• Objective: Launch a Six Sigma quality program and significantly improve


the level of quality at Flyrock

• Challenge: Getting the employees behind the program.

• Problem to solve: Express the value of Six Sigma quality to her


organization and get them to see the importance of reaching 6 sigma.
FLYROCK AND QUALITY

• About Flyrock Tires


• Major manufacturer of tires int eh US
• 5 Manufacturing facilities where tires are made
• 20 facilities for other various components and material used in tires

• Quality
• Recent fatal accidents involving tires (from other manufacturers)  reinforced need to focus
on quality.
• A lot of bad publicity for all tire manufacturers.
• All manufacturers needed to show they were working to ensure that problems did not arise
in the future.
• Lawsuits had been filed involving the way tires are built.
OBJECTIVE OF THIS CASE

• Give you an understanding of process capability in terms of various


measures.

• You should be able to quantify how an improvement in process


capability can help the performance of a process.
KEY POINTS

• Read through the tire manufacturing process.


• Each factory builds 10,000 tires per hour.

• First inspection point:


• After the tire is assembled and everything was in place for the final molding.

• Second inspection point:


• In the final finish area. If any blemishes or outside flaws, the tire is rejected.

• Audit:
• Internal problems or adhesion flaws were not visible.
• Manufacturers randomly pulled tires from production and cut them apart looking for defects

• Quality issues: Tolerance settings on various machines. Over time the settings vary due to
wear and tear on the machines. A machine may produce defective product even if the
machine had the correct setting. They implemented SPC (Statistical process control)
programs.
DEFECT RATES

• If each step resulted in 1% defects


• After 20 steps, only 81.2% of the product would
be good quality.
• At 10,000 tires per hour, this would be 1,880
defective tires per hour.
• Tolerance on the machines and the SPC program
• Extruder, rubber thickness spec of 400 +/- 10
thousandth of an inch (thou).
• If settings were accurate, the output produced
by the extruder had a thickness that was
normally distributed with a mean of 400 thou
and a standard deviation of 4 thou
1. If the extruder setting is accurate, what proportion of the
rubber extruded will be within specifications?

2. Douglas has asked operators to take a sample of 10 sheets


of rubber each hour from the extruder and measure the
thickness of each sheet. Based on the average thickness of
this sample, operators will decide whether the extrusion
process is in control or not. Given that Douglas plans Three
PART 1: Sigma control limits, what upper and lower control limits
ANSWER should she specify to the operators?

QUESTIONS 1,2
3. If a bearing is worn out, the extruder produces a mean
AND 3. thickness of 403 thou when the setting is 400 thou. Under
this condition, what proportion of defective sheets will the
extruder produce? Assuming the control limits in question
2, what is the probability that a sample taken from the
extruder with the worn bearings will be out of control? On
average, how many hours are likely to go by before the
worn bearing is detected?
1. Find the upper and lower specification limits
using the tolerances of the extruder
a. Upper Specification Limit, USL = 400 + 10 =
b. Lower Specification Limit, LSL = 400 – 10 =

2. What about the process? What do we know?


QUESTION 1 a. Normal distribution, Mean of 400, Std Dev of 4
STEPS thou
b. What is the probability that the rubber thickness
will lie within the specification limits when the
production output is as specified? (use Excel)
a. =NORMDIST(USL,400,4,1)-
NORMDIST(LSL,400,4,1)

3. How many defective tires per hour are


produced in the current process, knowing you
are producing 10,000 tires per hour?
1. What is given?
a. Sample Size, n = 10.
b. Population standard deviation = 4
c. Standard deviation of samples means = Std dev/ sq
rt (n)
QUESTION 2
2. What are the control limits?
STEPS a. Upper control limit, UCL = mean + 3 std dev
b. Lower control limit, LCL = mean – 3 std dev

3. What does it mean if all samples are within the


upper and lower control limit? What does it mean if
any of the samples are outside of the control limit?
1. Given: The output distribution has shifted as a result of
a worn bearing, the quality of output will change if no
action is taken.
a. Mean shift to 403 thou

2. Re-calculate the proportion of output within the


specification limits, the USL and LSL, with the new mean
shift of 403 thou.
a. . What does this mean?
QUESTION 3 4. How many parts will be defective per hour with the mean
STEPS: IMPACT shift?

OF A MEAN 5. How quickly will the control limits help detect this mean
shift so that the defect can be found quickly?
SHIFT a. Recalculate the upper and lower control limits with
the mean shift of 403 vs. 400 and the std dev of the sample
size calculated in question 2.
6. After the mean shift, what is the % probability that a
sample taken will be within control limits?
7. On average, how many samples will you have to take
before an out of control sample will appear and how many
defective tires will have been produced?

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