Stupid Responses to CARs - Long Term Corrections or Root Causes

Wes Bucey

Quite Involved in Discussions
#21
ralphsulser said:
We had a complaint about a shipment not arriving on time from a customer specified Trucking Company, FOB our plant. We tracked the shipment, and called the trucking company and found out the driver had been jailed on an outstanding warrant, and the freight was impounded.

At one company we had an internal answers we'd like to use for the numerous nuisance complaints from one of our automotive customers incompetent quality reps at a plant. "Here's a quarter, call someone who cares", or "Excuse me sir, but you obviously have me confused with someone who gives a sh**"
This guy was 1 1/2 hours away driving distance, when his engineering department made an engineering change that affected the fit of our part, he called in screaming that we absolutely had to "Air Freight" corrected parts same day. lol.gif
I am always amazed at the numerous ways a simple shipment can go awry. A couple of years ago we had an urgent document shipped from Canada to a Chicago suburb via Airborne. Package was picked up in Canada (Toronto suburb) at 10:00 am Friday for Saturday delivery. Saturday came and went - no delivery. Dozens of frantic phone calls later, we discover the package of documents was routed through customs in Canada, but Airborne didn't deliver it to customs until after customs closed. Customs reopened Monday morning. Airborne swore they'd expedite and have it on our doorstep by 10:00 am Monday. By noon, we were calling everybody, Airborne said it was on a truck in Chicago area and should be there "any minute." At 4:00 pm, still no package of documents (we could have driven to Toronto and back on Monday alone) - we are informed police are looking for truck - driver has not checked in - Airborne fears accident or (worse) highjacking because some of the cargo may have been valuable - Airborne is checking all shippers and receivers to determine if any cargo would have been ripe for highjacking.

6:00 pm Monday, we receive package from a guy in a passenger car.

Turns out original Airborne driver decided to make an extra hundred dollars using his Airborne truck to transport furniture for a neighbor. It took a little longer than he planned. Fine print in Airborne contract says all we got was refund of airfreight charge (after a 30 day "investigation period.") I figure I made that back by the following Wednesday in free drinks telling that story in saloons within two blocks of our plant.
 
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A

AllanJ

#22
Mustang said:
How about a "chair to keyboard interface problem"? :biglaugh:
If it was the chair that was at fault, presumably the auditor rejected its argument against the finding on the basis that it had no legs to stand on? Or was it the keyboard that could not show the right type of evidence?

All good schoolboy humor! ;)
 
Q

qualitytrec

#24
I do not have any that are that funny but they are stupid. For example a predicessor of mine wrote on an 8-D for a missing hole as the root cause:
"Operator did not clear part with broken punch from press and part was placed in container to be shipped."
Maybe it wouldn't be so bad but the problem was that the defect was caught and sorted for, then some moron took the part with a punch stuck in it and put it in the box to ship. There was no containment procedure. :bonk: :bonk:
 

Howard Atkins

Forum Administrator
Staff member
Admin
#25
I had a supplier that explained that corrosion that I complained about was "because it rained on the way to NY"

He alos explained dimensional non conformaties as "a result of residual stress in the metal"
 
C

Charmed

#26
And let's include the Doppler effect

Howard Atkins said:
I had a supplier that explained that corrosion that I complained about was "because it rained on the way to NY"

He alos explained dimensional non conformaties as "a result of residual stress in the metal"
Dear Howard:

Both are logical explanations, Howard. Might be a stretch, but rain does lead to corrosion and residual stresses, as they are relieved, do lead to a change in the dimensions of a component. I recently studied dimensions of plastic injection molded parts. The dimensions were changing even after a whole day had passed.

But, let me add the Doppler effect here - the explanation given by a physics student for running a red light. He said, it was green when he passed it and if the cop thought it was red, it must be the Doppler effect. I was told the judge accepted the student's argument and waived the ticket!

Charmed :)

P. S. It always seem to work for others, not for me!
 

SteelMaiden

Super Moderator
Super Moderator
#27
Charmed said:
Dear Howard:

Both are logical explanations, Howard. Might be a stretch, but rain does lead to corrosion and residual stresses, as they are relieved, do lead to a change in the dimensions of a component. I recently studied dimensions of plastic injection molded parts. The dimensions were changing even after a whole day had passed.
Charmed...
metals typically take longer to show corrosion pitting than one trip to NY, unless it was sent tied to the back of some ship and dragged through the ocean from some distant 3rd world country on a very slow boat:mg: and metals do not typically stress relieve themselves, this is accomplished through heat treating. Different animal than plastics altogether. But...If I were able to hire somebody to write up our investigations, I'd snap ya up in a moment:yes:
 
C

Charmed

#28
Snap ya up

SteelMaiden said:
Charmed...
metals typically take longer to show corrosion pitting than one trip to NY, unless it was sent tied to the back of some ship and dragged through the ocean from some distant 3rd world country on a very slow boat:mg: and metals do not typically stress relieve themselves, this is accomplished through heat treating. Different animal than plastics altogether. But...If I were able to hire somebody to write up our investigations, I'd snap ya up in a moment:yes:
Dear SteelMaiden:

Metals typically take longer ... yes.. I was thinking of the last few hours, or minutes, of this long journey that you contemplate. I have done a lot of heat treating of metals. Yes, they are a different animal from plastics. I think, the reason for the dimensional change that was seen in the injection molded parts was the more complex "molecular structure" of the plastics, or polymers, compared to the metals.

You can "snap" me if you want to.. am quite "ductile".. different animal from the plastics again. Haven't melted yet, walking in that rain...

Charmed :)
 
L

Laura M

#29
On an internal issue I received "We are doing the best with what we have."
My only response was "obviously."

When I was a new hire and answering warranty returns, my boss indicated he wanted me to be more thorough in some of my written analysis and wanted to read all my reports before they went out. One of the warranty returns was a carburetor and I found a fly in it. I wrote "The autopsy of the fly indicated no fuel in his lungs, therefore I do not believe the fly was the cause of the original problem and did not drowned in the carburetor." I had the fly mounted on a slide.

At first I thought I was in trouble, sense of humor was lacking...but then I gave him the final report. That was fun. He didn't review too many of my reports after that. I guess I was adequately trained at that point.
 

Mike S.

Happy to be Alive
Trusted Information Resource
#30
C Emmons said:
In defense of this response (because I did use it on rate occasion). If the process is in place, an associate is not performing, he has been trained, retrained, (training program is effective because the other 100 people are doing it as prescribed, you counsel him, etc. What else do you do? I used it in this case!
I agree with Cindy -- I think this can be an appropriate CA in some rare circumstances. I also believe in some rare circumstances "no action taken" is appropriate.
 
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