Start a new style on a line and hold its quality
A new style enters your line tomorrow: 25,000 pieces, moderate difficulty, three new operations the team has not done. You set the line up, run the first day, and keep quality while output ramps.
Who this is for: Line supervisors, production managers, industrial engineers and QA staff.
What you produce: A style launch file: the layout and workstation setup, the three new operation breakdowns, the day-one quality plan, and the review after day one.
Nobody marks this for you. Write your own answer, compare it with the guidance under each task, then mark the capstone done when you are satisfied with it. Your writing is saved on this device, and to your account when you sign in.
Task 1
Plan the line setup: layout, machines, attachments and workstation arrangement, with the ergonomic decision behind two workstations.
What a good answer contains: A good answer places material within reach, removes unnecessary handling, and chooses attachments and guides for consistency rather than speed alone.
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Task 2
Write the breakdown for the three new operations: steps, key points and the reason each key point matters.
What a good answer contains: A good answer keeps key points few and consequential, and states the reason so the operator retains it after the trainer leaves.
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Task 3
Write the day-one quality plan: checks at source, inline and endline, with the reaction to a repeated defect at each point.
What a good answer contains: A good answer puts the first check at the operation that creates the risk, defines the stop rule, and does not rely on endline inspection to find a process fault.
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Task 4
Review day one: the output, the top defect, the cause and the one change you make on day two.
What a good answer contains: A good answer separates learning-curve output loss from real problems, and its day-two change is specific and measurable.
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0/4 tasks have a written answer