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Use of Deductive Reasoning to Solve Off-Spec Parts IssueClientCannot disclose due to confidentiality agreement. ChallengeThe client is known for precision parts. When a run of their parts did not meet specifications they turned to their operations and suppliers to determine the source. Trying various equipment configurations they could not reproduce the failure. With only one part remaining from the bad run to analyze, they needed to get it right the first time. With their reputation on the line the client did not want to risk producing off-spec parts in the future. Their customer also wanted to know the source of the off-spec parts was known and being managed. SolutionAspen reviewed the reports provided by the client from their effort to resolve the issue, and pulled together a team of Aspen Associates experienced in injection molding. The team identified possible failure mechanisms and the characteristics that materials would posses due to those failures. A plan was developed so that all the measurements identified could be performed using the one part provided. The measurements pointed to a root cause based on the team's analysis and the client revised their manufacturing procedures to ensure the processing parameter was well-managed. The client was able to provide its customers with peace of mind that, not only was this issue resolved, but that any future issues could also be addressed. |
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