Problem Solving and Quality Improvement - Book Report/Review Example

Problem Solving and Quality improvement Due: Problem Solving and Quality improvement EXECUTIVE SUMMARY Most automotive systems in use today utilize front disk brakes and rear drum brakes. With disk brakes, the motor spins with the wheel and the pads move out and rub the rotor when brakes are applied. The manufacturing systems, tools and techniques of various firms influence the operational mechanism of the braking system. Several factors affect the braking system. The manufacturer specification and design, the raw materials, tools and techniques besides the care and maintenance of the motorist users affect the quality and durability of the braking system. The monitoring and control of the failure rate, if well incorporated into manufacturing process can enhance the quality of braking system and reduce the failure rate of the tools. Different firms have various design strategies that in turn influence the operation functionality of the braking system. Recently, the Stop IT LTD’s complaints from the clients have increased by 15% and a drop in sales by 8.3 percent. There has been an increasing witness by the firm losing of its customers to the competitors and subsequent dwindling of the reputation and fame of the firm. For instance, the media has noted that the company has lost its reputation to competitors. There have been reports that their replacements rates at the customer support services have soared high. Therefore, there needs to be a corrective action plan to restore the reputation and profit margin the company. The firms also needs to incorporate the operational excellence in a well designed project plan in its manufacturing processes, install automated monitoring and evaluation mechanisms and enhance its customer support services. KEY TERMS Brake failure, product improvement, and project plan CONTENTS PAGE...............................................................Page 1. List of illustrations/tables................................................................................4 2. Introduction.....................................................................................................5 3. Project plan......................................................................................................6 4. FMEA analysis..................................................................................................7 5. Corrective actions.............................................................................................8 6. Product improvement process........................................................................10 7. Recommendations...........................................................................................12 8. Referencing......................................................................................................14 9. Appendices.......................................................................................................15 List of illustrations/Tables Figure1 the Electronic Braking System (EBS)........................................................................15 INTRODUCTION In recent times, there has been a growing number of complaints and increasing failure rates and ineffectiveness of the brakes and the entire braking system components from our customers. The complaints have tarnished the reputation of the firm, lost the market share to the competitors and dropped in sales volume. The purpose of the report therefore, is to ascertain the causes of the problem, then suggest some of the plausible and long-term solutions to the problem. As noted by the (Ganaway, 2002, p1), most brake failures are caused by the introduction of water into the braking system. Water will cause rust and corrosion in the metal parts of the system and makes it difficult for the seals to operate correctly and produce high pressures needed for braking. Other cases are grease oil, which in most often, causes the linings to swell at spots on drum brake systems that later cause brakes to swell. The build-up of heat in the braking surfaces and a subsequent changes and reactions in the brake components causes the fading of braking system is mainly caused by the build up of the. It causes the loss of stopping power. Ganaway suggest that the appropriate equipment and material design, selection as well as good cooling mainly propagated by the user can reduce the problem. The project proposal therefore aims to examine and unravel the main causes of brake failure, its solutions. In addition, it aims to suggest some quality business processes such as systems design, reengineering process, the incorporation of quality tools and processes in their design procedures and the entire firm’s operation. The main aim is to reduce the failure rate and improve the quality of performance of the brakes. This restores the confidence in the stakeholders, drive up sales and enhances value. The recommendations and suggestion will be imperative to the management decision that will ensure that the quality as an aspect is enshrined into the entire firm’s processes. The management will respond by having a better scope of understanding that will enhance their responses and better make the firm able to respond the strategic postures. PROJECT PLAN The aim of the project plan is to enhance the overall performance of the brake system and restore the sales volume of the products in the market. It also aims to drive the firm to be globally competitive in the manufacturing industry by offering the quality products have a zero-rate failure and have a fair return on the stakeholders; a fair share of profit for the shareholders and a valuable benefit for the consumers. The plan is divided into three parts: statement of the problem, objects and outcomes. The statement of the problem Through there is a growth and expansion in the manufacturing industry, there has been a reduction in the sales of the Stop IT Ltd. This has been witnessed by an increasing complaints and return of defective products by the clients. They claim the braking system fails after a short time. Other complains that the rate of rusting is faster compared to others from other firm. The costs of quality such as repair and replacement is increasing, while the loss of clients is probable from the responses and reactions. The main problem is to manufacture the brakes and braking equipments that will be of higher quality and reduce the failure rate thereby pushing the sales volume up in future. Objectives of research proposal The project plan aims to: Assess and evaluate the operational mechanism of the current products. Identify some plausible reason for poor quality of the products such as design specification for quality, the process and technologies integrated in their manufacturing processes. Identify the probability of causes by different stakeholders: if the problems are customer-based or manufacturer-based and tailor in appropriate solutions. Identify and analysis the features of their products that seems to be causing the problem. Evaluate, summarise and recommend the most harmonised and efficient means of solving the same problem. Outcomes As a result of research, the Firm’s stakeholders will be able to: Customers will be able to take an effective and efficient approach towards the importance proper care and maintenance and all the dynamics that relate to it. Able to best track and monitor the braking system and their safety specifications. Develop both theoretical and feasible solutions both locally and nationally to address the problems and challenges in both short term and long-term aspects that relates to the performance of the product in the market. FMEA analysis on product A critical examination of the product reveals the following inefficiencies and failures. First, there have been complaints from the clients that the Antiblocking brake system (ABS) lights come on. This constantly locks the rear axle or the front axle.(WABCO,2004) Second, customers keep on complaining that when they accelerate, they feel the drag. This phenomenon is on and off, and report clearly indicates it mostly evidenced during the start-off and during high-speed momentums. Third, the brake pedal pulses when you apply brakes. It is a signal of the internal status of the internal working of the brakes.. Fourth, customers have also complained about hearing the sound of clicking, grinding or squeaking when brakes are applied. The sounds indicate a deeper problem in side that may have been caused by either technical or mechanical problem. Lastly, there has looming complaints about the vehicle grabbing or pulls itself on one side when driving. The possible dangers of break failure as witnessed by the above symptoms are that it may cause property damage, injury or even death. Therefore, there is need to offer corrective plans that would ensure such possible hazardous occurrences area are reduced or avoided although. Corrective action The main corrective action designed to reduce the brake failure and increase the effectiveness of the entire braking system will be to install the Electronic Braking System (EBS). The incorporation of the EBS, which was pioneered by WABCO, a leading global supplier of electronic braking systems, has significant benefits to the motorists. This was due to increasing traffic volume and growing customer demand that requires a continuous quality improvement in braking systems. In respect, two systems are offered: EBS evolution that utilises the ‘open structured ‘design and EBS compact that integrates different system components. As the author notes various benefits such as: a) Increase braking comforts By actuating the brake pedal, the driver defines the deceleration request. The EBS will electronically transmit these inputs to all the braking components. The shorter response time will provide a more comftable and finely tuned braking feeling, being independent of the vehicle’s loads situation. b) Superior vehicle safety Electronic activation of the EBS braking system clearly reduces response and build-up times in the brake cylinders. This in turn reduces the braking distance by several meters, which can be decisive in some situations. The ABS will ensure vehicle stability and steerability throughout the braking procedure. The Differential slip control (DSC) provides for automatic breaking force distribution between the front and rear axles are according to the load situation. In larger vehicle operations, the optimal alignment of the vehicle of the vehicle combination is greatly enhanced. There is a balance and great stability in all part of the vehicle. c) Optimized brake wear and easier maintenance. This provides a continuous brake wear monitoring as well as brake wear harmonization between axles. It can be used to align dates on maintenance with that of brake relining. The integration of non-wearing brakes such as retarder and engine brake also contributed to preserving brake lining materials and increases the wheel brake service life. This quality reduces the downtime and improves the cost-benefit ratio thus benefiting the motorist and non-motorists. d) EBS also improves the maintenance. A comprehensive integrated diagnostic and monitoring function enable EBS to permanently self-test. In case of restricted operability, warning features immediately prove the driver with relevant information that can quickly locate the cause of malfunctions. Besides, it reduces the maintenance and workshop times during repair and maintenance. PRODUCT IMPROVEMENT PROCESS Other tools and process to back-up the EBS include: Automatic braking system technology The technology is imminent as it senses collision with another vehicle, Person or obstacle. This mitigates possible danger such as high-speed approach to stop signs by applying brakes to slow the vehicle without any driver input. Other similar vital technology is the radar, sensors, infrared and ultrasonic. Other technologies that can be adopted include: Electronic brakeforce distribution Brake Assist Electronic Stability Control Automobile safety Risk compensation Recommendations Following the survey that was carried two weeks with an aim of restoring the quality of the products and subsequent confidence of clients, the following is hereby recommended; Managerial orientations The management will adopt management-by objective planning that will integrate all the manufacturing stakeholders from management to the junior level staff; The management will institute and support quality teams and circles to carefully examine quality-related problems, By instituting a continuous research and development programs, the management will continuously innovate and create products that suit customers’ tastes and preferences. The management will provide and sustain an innovative culture that embraces constant creativity and inventions. Technical orientations Relevant brake technologies such as will best be installed into the manufacturing systems f the organization Hiring of personnel will relevant skill, expertise and experience in design engineering that will spearhead relevant programs to the success of the organizations. Environmental orientations Adopting relevant technical orientations in their systems that will enhance their quality of their products Through research and development wings, relevant intelligence will be conveyed to the management about the demand and supply of product in the market. This will enhance the profitability, better survival rates and a sustained reputation of the firm. Constantly reviewing the business environment especially the competitor so that product differentiation strategies can e adopted. REFERENCES www.CNN.com/ brakes systems Gaither, N., 1980.production and operation management. Hinsdale, III: Dryden. Gary Ganaway, Air Disc Brake Production, Use & Performance, NDIA Tactical Wheeled Vehicles Conference, Monterey California, 28 January 2002. Accessed 2010/01. Rothberg, R., 1981. Corporate strategy and product innovation. New York: Free Press The Electronic Braking system (EBS) New Generation, 2004. WABCO, http://www.wabco-auto.com/uploads/media/Product_Brochure-EBS_04.pdf . Appendices The EBS The EBS components Read More