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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
develop a diagram
a few seconds ago
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Helpful Assistant
Here is a cause-and-effect relationship chart for the scenario you provided:
The main impacted goal was to restart production at restart production at restart production at Cisco
Metals after the Christmas shutdown within the expected timeline.
The direct cause of the delay was the maintenance staff not having the correct (#62-2) grinding wheels
to remove the furnace coils. This prevented them from completing the repair work on time.
A necessary cause of the maintenance staff not having the correct wheels was that purchasing had
substituted the incorrect (#62) grinding wheels when fulfilling the original request.
A root cause of the incorrect substitution was that purchasing regularly substitutes less expensive parts
without verifying they provide the same function. In this case, the material composition was different
between the #62 and #62-2 wheels.
Some additional effects of not having the correct grinding wheels were:
The #62 wheels cut much slower, prolonging the repair work.
The #62 wheels kept breaking during use, requiring work stoppages to change wheels. This further
delayed completion.
Emergency ordering of the correct #62-2 wheels was required once the issue was discovered,
introducing additional delay.
The production line startup was delayed by 2 days, costing $7000 per day in lost revenue.
Additional crews of 14 people each had to work overtime due to the maintenance delay, increasing
costs.
Let me know if you need any part of the cause-and-effect relationship explained further or if you have
additional questions!
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