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 presented here are based on real-world situations that are encountered by workers in manufacturing environments. 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
Nelson works for a paper mill that fabricates a variety of products for numerous customers. One product is the paper bags that are supplied to a food company. The bags are used to package microwave popcorn. Not long after becoming supervisor for production of these bags, Nelson was barraged with complaints from the food company about the quality of the bags. The bags were exploding during the microwave process. This breakage caused a mess and the food company's customers were switching brands. Nelson's company was on the verge of losing a valuable customer.