WESTOVER

ELECTRICAL
EXECUTIVE
SUMMARY
WESTOVER ELECTRICAL,
INC.
Houston Manufacturer of
wire windings
PROBLEM STATEMENT
The root cause of the increasing rejected products
needs to be found to prevent further losses
WESTOVER ELECTRICAL
WINDING OPERATION
FLOW CHART
1.Production of windings by Machine 1, 2
and 3
2.Windings sent to Quality Control
3.Inspection of electrical windings

4.Windings sent to packaging
5.Packaging personnel inspect their
work
6.Defects found are corrected on the
spot
7.Windings are packaged

Too many windings
are found to be
defective and require
reworking before they
can be packaged

0
5
10
15
20
25
30
35
1 2 3 4 5 8 9 10 11 12 15 16 17 18 19 22 23 24 25 26 29 30
N
U
M
B
E
R

O
F

R
E
J
E
C
T
S

DATES
Reject Log in January
Bad Wind Twisted Wire Broken Leads
Abraded Wire Wrong Core Wrong Wire
Failed Electric Test Total
STATISTICAL PROCESS
CONTROL CHART

0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
10
20
30
40
50
60
70
80
90
Abraded
Wire
Failed
Electrical
Test
Broken
Leads
Wrong
Wire
Bad Wind Twisted
Wire
Wrong
Core
PROBLEM AREAS
OCCURRENCES CUMULATIVE PERCENT
WESTOVER ELECTRICAL
WINDING OPERATION FLOW
CHART
TOTAL DEFECTS

Total Defects per
Winder
Winder 1 77
Winder 2 42
Winder 3 142
RECOMMENDATI
ONS

WESTOVER ELECTRICAL
WINDING OPERATION FLOW
CHART
1) Production of windings by Machine 1,
2 and 3
2) Windings sent to Quality Control
3) Inspection of electrical windings
4) Rework of items sent from Machine 1
and 3 to lessen defects
5)Windings sent to packaging
6)Packaging personnel inspect their
work
7)Defects found by personnel are
corrected on the spot
8)Windings are packaged
THE ASSUMPTION IS 80% OF REWORK
TURNOUT WILL BE FLAWLESS WITH A
MARGIN OF 20% ERROR.

Winders 3 and 1
Total defects
175
Number of original defects
less rework
86
Percentage difference after
rework
67.05% over 32.95%
remaining defects
REPLACE WINDER
MACHINE 3
Winder 3 defects 0
Number of original defects
less rework
119
Percentage difference after
rework
54.41% over 45.59% remaining
defects
ASSUMPTION : 65% OF DEFECTS FOR EACH MACHINE
WILL GO DOWN WITH A MARGIN OF 35% DEFECTS
REMAINING.
Winder 1, 2 and 3 261 x 65%= 170
Number of original
defects less rework
91
Percentage difference
after rework
65.13% over 34.87%
remaining defects
MACHINE OVER-ALL
MAINTENANCE
BEST
SOLUTION
1
ST
RECOMMENDATION
The defects were mainly concentrated in
the machines 1 and 3 so the problems
were mainly caused by this 2 machines
and remedying them would lessen the
defects that production will generate.


WHY NOT THE 2
ND

RECOMMENDATION ?
Higher costs
Higher risks
WHY NOT THE 3
RD

RECOMMENDATION?
Lower cost but greater
risk
CONCLUSIO
N