Worked case studies

One problem, followed from the customer complaint to closure, with every method in the order a real team would use it. The cases are illustrative: fictional companies and data, but every statistic is calculated from the published data and opens in the tools.

Metal stamping · 8DWorked 8D case: oval, burred holes and punch breakage in stamping

An illustrative end-to-end case from a progressive die: customer complaint on Ø 8.5 mm pierced holes, containment, is / is not, Pareto, Ishikawa, 5 Why, MSA, Cpk before and after, Weibull punch life, PFMEA with AP, control plan, LPA and closure.

Tools: 8D Report, Pareto Chart, Fishbone Diagram, 5 Why Analysis, Type 1 Gauge Study (Cg, Cgk), Gage R&R (MSA), Process Capability & Control Charts, Weibull Analysis, FMEA Worksheet, Control Plan, Layered Process Audit (LPA), CAPA and NCR Tracker