Responsibility for Product Quality Problems in Sequential Manufacturing: A Case Study From the Meat Industry

Quality Management Journal vol. 18 issue 1 - January 2011

Abstract: [This abstract is based on the author’s abstract.] This case study examines a meat industry company that developed an innovative product but did not achieve expected profits due to high levels of production rejects. The production staff believed the product development team had handed over a product with unresolved production issues while the product development team believed the production staff was not following production procedures. Use of statistical process control reduced production rejects from 22 percent to seven percent. Further reduction was not possible because the product design team had failed to consider manufacturability issues when designing the product and the production staff was not following the production process. This paper also shows the use of variation transmission analysis, a technique to estimate the variation due to different stages of the production process and prioritize the sources of variability.

Keywords: Case study; Design for manufacturability (DFM); Estimation; Food and Drug industry; Food processing; Process capability (Cp); Production; Quality improvement (QI); Statistical process control (SPC); Variation

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