With its railroad access and presence of numerous automobile factories, Milwauke

With its railroad access and presence of numerous automobile factories, Milwaukee Junc􀆟on was
considered the cradle of the automo􀆟ve industry at the turn of the 20th century. Now, 100 years later,
the automo􀆟ve industry looks to make Milwaukee Junc􀆟on the launchpad for its next century of growth
and development. Instead of wooden horse carriages and body shops, electric vehicle components will
be manufactured in this historic industrial hub.
As Wayne State students, you understand Detroit and what it takes to thrive in the City of Champions
and home of the automo􀆟ve industry. The Milwaukee Junc􀆟on Revitaliza􀆟on Project is not only
significant to the next genera􀆟on of automobiles, but the success of the facili􀆟es is cri􀆟cal to the
resurgence of Detroit and Southeast Michigan.
You’ve been selected to be part of the team that will stamp automo􀆟ve washers in a reclaimed, historic
automo􀆟ve facility on Pique􀆩e Avenue. The plant will have 20 high speed stamping machines that will
produce washers and special components for EV motor assemblies. The 􀆟ming for this launch is almost
as 􀆟ght as the part tolerances, but it’s nothing that is insurmountable.
As men􀆟oned before, your facility has 20 high speed presses, and you are responsible for launching a
compound die that will be responsible for stamping 5M washers per year. The press, known as Press 20,
will run at capacity, which includes appropriate 􀆟me for die maintenance, and will be dedicated to this
die for the en􀆟re year. To be clear, Press 20 does not have capacity for any more parts.
To launch the product, you’ll need to complete the following tasks to receive approval from your
customer to begin produc􀆟on. All data you need will be taken from a preliminary part run, a􀅌er which
you will report the results to your customer. The following informa􀆟on will be used to complete your
part approval.
Part specifica􀆟ons:
 Outside Diameter: 55 mm ±5 mm
 Inside Diameter: 20 mm ±5 mm
 Material Thickness: 0.5 mm ±0.1 mm
 Material Chemistry: See Material Cert
Incoming Material:
 Coil Width: 60 mm
 Material Thickness: 0.5 mm
Process Parameters:
 100 strokes per minute
 Dies sharpened every 75,000 cycles
 Die perishable details are replaced every 500,000 cycles
 Die gaps: 10% of material thickness
Packing:
 125 pieces per box
 Nine boxes per pallet layer
WSU Supply Chain Management – Quality Case Study – October 2023
 Five layers on the pallet
Process Steps:
 Receiving
 Stamping
 Pack & Count
 Shipping
To achieve part approval, you will need to complete the following items (blank forms are included):
1. Process flow chart
2. Control Plan (include process and product parameters)
3. Part Layout (six parts)
4. Material Results (chemistry – from cert)
5. Test Results (material physical tes􀆟ng – from cert)
6. PSW warrant.
Once you complete all these documents, you will assemble them as a PDF package and present your
results to the remainder of your team and see if your customer/professor signs off on your PPAP.
Unfortunately, the following scenarios occur, and you need to complete new part approvals for each of
these situa􀆟ons. No worries – this happens all the 􀆟me, and you should be thankful that it’s occurring
before you get too far in produc􀆟on. Review the content from above and apply the changes iden􀆟fied in
each scenario, but be smart and see what can be common and what needs to be recreated:
1. Good news! Your washers are a success, but your customer needs more of them. Based on your
opera􀆟ng pa􀆩ern, you will need to buy another press and build a new die to stamp the now 7M
parts required each year. Complete a part approval for the new press, known as Press 21, and
die and submit those results with the exis􀆟ng results to your customer.
2. Your steel supplier just informed you that they are increasing your pricing by 75%, so you have
decided to find a new supplier. Complete the part approval process for this new steel supplier.
3. Bad news – your building has a leak. As it’s an old building, you’re not en􀆟rely surprised, but you
cannot let the leak ruin your machine and tooling. You’ll have to move your press so it’s not
under the leak and complete all the approval process for the change.
4. Engineering changes occur all the 􀆟me, and your customer just changed the outside diameter of
your washer from 55 mm to 60 mm. No worries – the tolerance is s􀆟ll ±5 mm. Complete the
part approval for the new diameter of the part.
All submissions will be submi􀆩ed in a PDF file to your customer’s supplier quality engineer, Dr. Rightmer.
Dr. Rightmer will review and either approve or reject your part submission based on the completeness
and accuracy of the data you provide. Please label each submission accordingly:
1. – – Ini􀆟al PPAP – October 2023
2. – – Change Scenario 1 PPAP – October 2023
3. – – Change Scenario 2 PPAP – October 2023
4. – – Change Scenario 3 PPAP – October 2023
5. – – Change Scenario 4 PPAP – October 2023