CASE STUDY:

TOLEDO
MANUFACTURIN
G QUALITY
CONTROL
SYNDICATES 2
TEAM MEMBERS

Claudhia Devita
Astie Asty Aprilia Christy Putri Dias
Kurniati Firdausya Kusuma Chang Saraswati Natrasuari
29322439 29322474 29321542 29322493
29322464 29322492

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 → TOLEDO CUSTOM MANUFACTURING: QUALITY CONTROL

CASE
OVERVIEW
Toledo Custom Manufacturing (TCM) is a company located in Ohio that produces
metal parts based on customer specifications, using a range of machines including
lathes, grinders, and numerically controlled (NC) machines. TCM recently
received an order to machine 5000 push rods, which must meet precise
specifications to ensure hydraulic leaks do not occur. To ensure that the parts meet
the specifications, TCM will use two machines, each with its own operator, and
construct control charts to determine whether the process is in control. If the
process is out of control, TCM will need to fix it before proceeding. The customer
requested that final control charts be forwarded to them along with the 60
parts produced by the two machines. They also want the charts to be maintained
by taking hourly samples and submitted along with future batches of parts. The
process capability index will be calculated to ensure that the process is capable of
meeting the specifications.
Specifications:
0.5 ± 0.05

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QUESTION 1
Calculate the control charts (UCL, CL, and
LCL) for each operator-machine combination
separately.

Do this for both x-bar (average) and range

charts. Draw conclusions from the charts about
each operator- machine combination.

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 → QUESTION 1

Calculate the control charts (UCL, CL, and LCL) for each operator-machine combination
separately. Do this for both x-bar (average) and range charts.
Draw conclusions from the charts about each operator- machine combination.
Machine 1:

X-BAR CHART R-CHART

CL UCL LCL CL UCL LCL
0.50 0.50 0.49 0.007 0.015 -0.002 (0)

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Control Charts Calculation Click Here
 → QUESTION 1

Calculate the control charts (UCL, CL, and LCL) for each operator-machine combination
separately. Do this for both x-bar (average) and range charts.
Draw conclusions from the charts about each operator- machine combination.
Machine 2:

X-BAR CHART R-CHART

CL UCL LCL CL UCL LCL
0.502 0.50 0.49 0.007 0.015 -0.002 (0)

Control Charts Calculation Click Here 6

 → QUESTION 1

Calculate the control charts (UCL, CL, and LCL) for each operator-machine combination
separately. Do this for both x-bar (average) and range charts.
Draw conclusions from the charts about each operator- machine combination.
Conclusion:
The use the X-bar and R-chart pair is to monitor the process performance of continuous data. They are a standardized chart for
variables data and help determine if a particular process is predictable and stable.

Referring to the previous slides on our calculations and the control charts for both operator-machine combinations, it can be inferred
that operator 1 and machine 1 are exhibiting a controlled process. This is evident from the fact that all the sample averages and
ranges fall within the established control limits.
On the other hand, it can be concluded that the process of operator 2 and machine 2 is not in control.

While the range chart appears to be in control, there are two sample averages that are above or just hitting the upper control limits,
and one sample average that is just hitting the lower limit on the average chart. These are three sample average falling outside the
tolerance limits indicate that the process of operator 2 and machine 2 is out of control.

Control Charts Calculation Click Here

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QUESTION 2
What should be done based on the calculations
from question 1?

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 → QUESTION 2

What should be done based on the calculations from

question 1?
Given that operator 1 and machine 1 are in control, the process doesn't require any changes, except for complying with the customer's request to take 5 rod
samples every hour to maintain control. However, operator 2 and machine 2 are not in control, and therefore, TCM must modify the process before
continuing to manufacture the rods.

Here are possible actions that TCM could do:

- Machinery investigation to determine whether it function properly by checking for example the worn parts, misalignment, incorrect settings etc.
- Once the machinery is checked or repaired, the next step is to make any necessary adjustments to the process to ensure that the steel rods produced
fall within the required tolerance range. This include changing the speed or pressure of the machine, adjusting the temperature, or modifying other
variables that can impact the process output.
- TCM could also investigate the operator's training and attention to detail to improve the quality of the samples. Studies have shown that increasing
workforce education can lead to an 8.6% increase in productivity.

Once the root cause of the process being out of control is determined and addressed, operator 2 and machine 2 should produce six new samples of five parts
each, and new control charts should be calculated to ensure the process is now under control. Once the process is verified, both operators and machines can
work together to manufacture the customer's order.

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QUESTION 3
What is the process capability for each
operator - Machine combination?

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 → QUESTION 3

What is the process capability for each operator - machine combination?

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 → QUESTION 3

What is the process capability for each operator - machine combination?

Machine 1 Machine 2

Notes: Cp CpK

Cp : Process Capability
Operator 1 - Machine 1 0.53 0.53
Cpk: Process Capability Index
Operator 2 - Machine 2 0.49 0.27

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QUESTION 4
Can you be sure that all the parts
produced by in-control processes will met
the specification?

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 → QUESTION 4

Can you be sure that all the parts produced by in-control

processes will meet the specification?
We cannot be sure. Based on the data that we have calculated, both Cp and Cpk index are below
1, which means that the process do not delivers all same output with the expected
specifications. On top of that, even machine 1 is in control but there are lot of variance during
the production process from the operator. The possible solution is decrease the deviation, or
lower the variance in the on-going developed parts to ensure all parts meet the requirements. It
can be done through these following actions:

1. Machine – It should have a regular maintenance to check the quality of the machine and ensure that it is in its excellent condition.

2. Operator – Training and attentive are the essential factors for the staff members concerning controlling production because the
specification of metal requires competence and expertise from the producers in every position.

Besides, management also needs to add more sampling to represent more accurate data since what we have now is only 1.2%. We
would like to propose additional sample to at least 357 sample to have confidence level to 95%.
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