After identifying these categories, the team conducted further root cause analysis to determine the source of the defects. They found that
lack
of
standardized
communication,
absence
of
quality checks, and human error were the most common defect causes. The team ultimately delivered five recommendations to LSI, along with a cost-benefit analysis of the solutions.
The
top
two
recommendations were to update and
improve
documents
standard
and
to
work
hire
a
dedicated custom produce quality technician.
To
support
the
implementation
of
these
recommendations,
the
team
revised several standard work documents
to
reduce
high-
incidence defects, such as
mixing up easily confused parts (ie, including a left-side bracket instead of a right-side bracket in a delivery). Creating the new quality technician role would allow engineers and welders more time to focus on their respective jobs, as well as centralize responsibility for maintaining systems and documentation, and oversee overall quality improvement. The benefits of this new position are projected to outweigh the cost. If LSI implements all five recommendations, the customer-reported defect reports are expected to decrease by at least 20% over the coming year, as well as provide cost savings. Reflecting on their project experience, the team emphasized their increased appreciation for the importance of flexibility, clear documentation, and standardization. These new graduates are now swinging their way into summer with a better understanding of playgrounds and their futures.
Industrial and Systems Engineering
09