A Plant Manager at a US manufacturing plant found that that the biggest problem with scrap losses was oversized bores on cylinder blocks. The department supervisor explained that process was complex and difficult for employees to master. To check out this explanation the manager obtained previous scrap reports and plotted the daily percentage of scrap on a run chart and then identified what employees had worked on that job in the previous three months. The result showed no link between scrap an...

BPIR Categories

5.5.6 Inspections, tests, process/performance audits
14.1.4 Gather and integrate performance data.
14.1.5 Analyse performance data.

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