Virtual Tours – Chapter 4 (Statistical Process Control)

BMW (http://bmwusfactory.com/build/)

This virtual tour of the BMW plant in Spartanburg, South Carolina is one of the slickest sites on the Internet. Tours are provided for both the X5 SUV and the Z4 Roadster. Each tour includes a series of pages with text and excellent photos that encompass the body shop, paint shop and assembly line. You navigate through the steps in the manufacturing process from a timeline. The site also includes separate links for “efficiency” and “quality control.” Each of these links includes narration and photos that discuss these facets of BMW auto manufacturing. For example, the “efficiency” link discusses how BMW uses flexible manufacturing and 3D CAD programs for design.

1. BMW measures every inch of every vehicle for what level of tolerance?

2. What random tests does BMW perform daily and each week to insure product quality?

3. What is a “broadcast sheet” and how is it used in the quality control process?

4. What are BMW employees called?

5. At the BMW Spartanburg, SC plant the X5 and Z4 have the smallest tolerances of all BMW vehicles. How does BMW measure tolerances in the quality control process and how does this compare with other auto manufacturers?

6. What takes place at “Final Body Inspection” for the BMW X5?

7. What takes place at the BMW X5 “E-Coat Inspection Deck?”

8. What takes place at the BMW X5 Sanding and Inspection Deck?’

9. At what point in the assembly process for the BMW X5 are electrical components tested?

10. What tests occur at the final “Diagnostics” station for the BMW X5?

11. What occurs at the “Final Inspection” station for the BMW X5?

C&R Manufacturing (http://forecast.umkc.edu/vtours/compback.htm)

C&R is a small, highly automated manufacturing company (i.e., job shop) near Kansas City. The tour is broken down into 12 specific topic or functional areas, for example, “What is a Job Shop?,” “Marketing,” “Human Resources,” and “ISO 9000 and Quality.” Each topic (page) includes a detailed written description with examples of how this topic or function relates to C&R. Each topic page includes several photos. There are no videos, sound or animations.

1. To what extent does C&R make use of statistical process control in its work?

2. What degree of tolerance can C&R machines maintain?

3. How does C&R make use of SPC in the production of valves for SOR, INC.?

4. To what extent does C&R inspect competed parts?

5. What procedure does C&R use to inspect completed parts?

6. C&R hasn’t lost a customer or even one part order in the past 10 years? To what three things does it attribute this level of success?