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Doors and Windows Company | Assignment

Added on - 22 Sep 2019

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A1 Doors and WindowsSection BB Assignment #2 Due: Friday Mar 22nd.A1 Doors and Windows is a small company located in the GTA. The company employs60 employees in its one location. Much of their product is sold to small companies whothen sell and install their products to the retail home market. A small part of theirbusiness is to independent contractors for new home builds. A1 does not do anyinstallation of the product or selling to the final consumer. All product is made to order.The company competes based on reasonable prices, competitive delivery times andaims to ship all orders with two weeks.David McLellan is the new VP of Operations and he has been very concerned about theincreasing problem with rejected products found during the manufacturing operation.David feels strongly that there is too much product rejected. "Rejects have been a largeproblem here", said McLellan in the weekly management meeting. He feels strongly thatdata must be collected and analyzed in order to begin fixing the problems.As a new employee at A1, and a graduate of Seneca College, you have been asked tohelp review and analyze the quality data for A1. Although you will not make technicalrecommendations, you should be able to help them figure out what the problems areand to point them in the right direction.Your Task:You have been asked to look at the quality data for the entire facility for the month ofJanuary. You have also been asked to tour the facility, talk to employees, and gatherinformation to make recommendations.Process Overview:There are three assembly areas where employees and machines assemble productionruns of various orders of windows and doors. There is always one inspector in each areawho performs 100% inspection, and another employee who packages the product andloads them onto skids for delivery to customer’s facility. Each order may contain as fewas six items, or for a larger customer, up to 60 items. It is important that each order isshipped complete or a separate truck may have to be dispatched with the missingitem(s).Currently, products that are found faulty by the inspector are to be sent to a specialteam of 2 employees, in the repair department. These employees are responsible toevaluate, repair and document their work. Some product cannot be repaired and isdesignated as “scrap” and sent to the garbage. The remainder is repaired. Often productneeds to be repaired right away so the entire order is not delayed.1
There is a constant supply of products waiting to be evaluated by the repair team.Scheduling the work in this department and the number of “rush” jobs is problematic.After being repaired, products are returned to the final inspection area at the end ofthe assembly area that it came from. The inspector must look at the repaired product tomake sure that the defect is properly repaired.Components to assemble the windows and doors are received in large quantities fromCanadian and American suppliers. These supplies include aluminum, glass, trim, and avariety of other components such as latches, handles, screen etc. After inspection andstorage, quantities for one day's production are sent directly to the different productionareas, every night for the next day's production. Goods that do not pass receivinginspection are held, and sent back to suppliers. There is a backlog of goods waiting to bereturned to suppliers.Frequently, a product is returned from the customer due to an error in the dimension ofa product or a poor fit. This becomes a priority to replace, as it can hold up an entireinstallation.Your Actions:Your discussions with supervisors in the facility did not yield any definite clues as to thereasons for all the defects. There seemed to be many different types of rejects piled invarious locations throughout the facility. The employees assembling the product seemto be experienced, but do complain about being rushed to complete the orders so thattrucks can depart with full orders.Your next stop was at the Quality Control Department, where you obtained the recordsfor the Assembly Department rejects, for the last month.Assignment:Compile a report usingWORDthat includes the following1. Cover page and Table of Contents, page numbers, professional appearance (2 marks)2. Executive Summary. You should write this part after you have covered all the issues ofthis assignment, but it should appear at the beginning of your report. In ONEPARAGRAPH, summarize,using numberswhat are the main sources of errors. Wheredoes A1 need to concentrate their Quality efforts?(2 marks)3. How will you go about getting the information you need in order to complete therequested report? Who will you speak to and what questions will you ask?(max 2paragraphs) ( 2 marks)2
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