ABSTRACT
The importance of complying with established routings, job procedures, consistent work, and auditing of operations is beneficial to preventing flaws. Chance does not create repetitive flaws, but inconsistencies do. In most cases, the observation and recognition of those circumstances that contribute to defects will lead to an imaginative means of solution. This chapter explains the problem as experienced by a customer that was assembling complex electrical control units and was experiencing line rejects after the final assembly. It considers the problem characteristics and the condition that allowed the problem to be resolved. It was found that the problem was caused by a relatively new employee who was using a processed wafer to troubleshoot a problem in their manufacturing system. The operation included the use of an outside supplier to augment the initial machining and to provide the final truck head component assembly to pass an initial line installation pretest.
