Everyone who has faced a production problem with a need to solve the problem by using production data can relate to the notion of a brain teaser. The brain teasers have three parts: (1) the situation, (2) available data or other supporting information and (3) questions that various workers want answered for continual improvement. Recommended solutions follow in the next issue and on the Web at Quality Online (www.qualitymag.com).
Situation
Derek has been a machine operator for 23 years and has developed a sense of when his machine is not operating optimally. At times Derek notices that the machine makes strange noises, appears to slow down for some parts, or pauses slightly during the machining operation. Derek machines castings that are supplied by three companies and he suspects that differences among the castings have impacted the part's critical dimensions. Derek has talked to his supervisor and other operators about his suspicions, but everyone says the suppliers must be OK because the parts meet specifications.