Suggestions for Ishikawa for hyperdetailed customer - plastic molding automotive parts

[doinQC]

Hi quality folks,

Does anyone have suggestions on how to satisfy a customer who is asking for pages of Ishikawa possibilities on a very minor flash issue? I have already presented at least 3 options for each topic, but the reply Ive gotten is that I haven't considered enough possibilities or given detailed enough reasons for exclusion. Anyone have an example, or advice? (The volume of attention they are requiring is monopolizing all my time, to the exclusion of being able to address other customer concerns & duties.)

Here's 1 line of "occurrence" ...separate report for detection

Ishikawa
Cause Item (Possible Cause) Operator training
Description Operator loads process in press f rom Data Memory
Relevancy for consideration Operator cannot change
Reason for excluding an Excluded Cause Locked process (Password Protected)

Thanks in advance!

 

[Ninja]

Possibly the opposite of what you're looking for, if so please forgive me.

I would get a decent idea of what they wanted (you may already have this) and send them (via salesperson, approved by management) a budgetary quote for the time it would take to provide what they want (it would have a decent profit margin built in).
When a customer's demands exceed the profit potential of that customer, it has to be a business decision which way to go.

It isn't just you...you're part of a business team.

 

[doinQC]

Hi quality folks,

Does anyone have suggestions on how to satisfy a customer who is asking for pages of Ishikawa possibilities on a very minor flash issue? I have already presented at least 3 options for each topic, but the reply Ive gotten is that I haven't considered enough possibilities or given detailed enough reasons for exclusion. Anyone have an example, or advice? (The volume of attention they are requiring is monopolizing all my time, to the exclusion of being able to address other customer concerns & duties.)

Here's 1 line of "occurrence" ...separate report for detection

Ishikawa
Cause Item (Possible Cause) Operator training
Description Operator loads process in press f rom Data Memory
Relevancy for consideration Operator cannot change
Reason for excluding an Excluded Cause Locked process (Password Protected)

Thanks in advance!

Possibly the opposite of what you're looking for, if so please forgive me.

I would get a decent idea of what they wanted (you may already have this) and send them (via salesperson, approved by management) a budgetary quote for the time it would take to provide what they want (it would have a decent profit margin built in).
When a customer's demands exceed the profit potential of that customer, it has to be a business decision which way to go.

It isn't just you...you're part of a business team.

Interesting perspective, thanks.

 

[Ninja]

The volume of attention they are requiring is monopolizing all my time, to the exclusion of being able to address other customer concerns & duties.

Right there, it becomes a business decision of whether or not they are a customer worth having.
Don't get me wrong, they may well be...but the "attributed overhead cost" just went above projections by the amount of your salary and benefits and incidentals. That's when the business side has to step in.

 

[optomist1]

please share, is this an automotive part, if so is it a class A surface?

 

[Johnny Quality]

Is creating documentation to please the customer primary to fixing the problem?

 

[AgnieszkaSz]

First, I would ask the customer why this flash annoys them so much - is it visible? does it pose any assembly problem? Second - how often the flash happens? If seldom or very seldom, this can be stochastic nature of injection moulding itself; if often - this may be a systematic problem, like wear and tear of the tool. Your statement that the operator cannot change the settings - OK, operator should not be able to do this; but even if you must keep the process parameters within validated process window, it is always a window, some parameters can be altered within preset tolerance. A setter should be able to adjust the process. We keep two setters at every shift and they have a lot to do, even with very long series. So I would address at least tool issues and personnel skills, meaning setters.

 

[Bev D]

Do you actually know the cause? (I mean with data and you were able to turn it on and turn it off)

 

[Miner]

Flash causes usually fall into one of these categories:

• Tool design
• Tool maintenance
• Process parameters

 

[Brakeman]

What does your PFMEA say causes flash? You wouldn't put Operator Training as a risk factor in your PFMEA so I don't understand why you would mention it here. Flash would seem to be a molding system set-up issue.