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Conestoga College *

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8000-4

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Mechanical Engineering

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Dec 6, 2023

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docx

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3 Instructions review the Scenario – Cisco Metals On January 3, 2018, following the Christmas production shutdown, there was a 2 day delay in the start-up of a production line at Cisco Metals. Over the Christmas shutdown, there was repair work happening on the furnaces in the facility. Thirty coils were being replaced in one of the furnaces. The delay cost 2 days of production at about $7000 per day. There were also 14 additional people on each crew working around the clock because of the maintenance delay. This delay was due to the maintenance staff not having the grinding wheels needed to cut this particular coil from the furnace. The grinding wheels they had were #62 and they needed #62-2. Maintenance had put in a request 4 weeks ago and received the wheels a week later, but did not realize they had the incorrect grinding wheels until the job was started. The purchasing department substituted #62 wheels for the #62-2 wheels that were originally requested. They appeared to be the same wheel and the #62 wheels were $40 less than the #62-2 grinding wheels. Purchasing regularly substitutes a less expensive part if it provides the same function. In this case, the material was different between the two grinding wheels and had been selected specifically for cutting the alloy that had been used in the furnace coils. The #62 wheels cut much slower and kept breaking which was dangerous though no one had been injured. The delay came from the slow cutting time, work stoppage, and waiting for the original #62-2 wheels that were now being sent on an emergency basis. 2) Create a Cause-and-Effect Relationship Chart Start small using a basic linear flow. Then use questions to fill in the details by adding causes horizontally and vertically to reflect additional information and/or "necessary and sufficient logic". Should contain, must have/follow these The causes identified are sufficient to produce the associated effect The causes identified in the map are necessary to produce the linked effects Impacted goal is properly identified Enough detail is provided in the map that the final causes are solved, they will prevent the issue. Evidence of causes is provided where possible. Leadership, ideas, and collaboration shown in MSTeams and/or participation in at least one meeting with group a few seconds ago Good response What do you like about this response? How was it good?

Cancel Submit Bad response What was the issue with this response? How could it be improved? Cancel Submit Helpful Assistant Here is a cause-and-effect relationship chart for the scenario you provided: The main impacted goal was to restart production at Cisco Metals after the Christmas shutdown. Cause: Maintenance staff requested incorrect grinding wheels (#62 instead of #62-2) for replacing furnace coils Effect: Incorrect grinding wheels (#62) were received by maintenance Cause: Purchasing department substituted cheaper #62 wheels without verifying they were suitable Effect: Maintenance started job with #62 wheels, not realizing they were incorrect Cause: #62 wheels cut much slower than required #62-2 wheels Effect: Work took longer than expected due to slow cutting Cause: #62 wheels kept breaking during cutting Effect: Work had to stop frequently to replace broken wheels, further delaying progress Cause: Emergency request was made for correct #62-2 wheels Effect: Delay in receiving #62-2 wheels from emergency order Effect: 2 day production delay at Cisco Metals Effect: Increased labor costs of $14,000 due to extra crew members working overtime The identified causes are sufficient to explain why the production delay occurred. Ensuring the correct grinding wheels (#62-2) are requested and received is necessary to prevent similar delays in the future. The purchasing department substituting an incorrect part without verification was a root cause. Providing more details on part specifications or getting approval for substitutions could help solve this issue. Let me know if any part of the cause-and-effect relationship chart needs more explanation or expansion.

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