1. Presented by Dr. Joan Burtner Certified Quality Engineer Associate Professor and Chair, Dept. of Industrial Engineering and Industrial Management Mercer University

2.  Article Title: Exclusive: Takata changes chemical compound involved in air bag recalls  Authors: Maki Shiraki Paul Lienert Ben Klaymen  Wednesday Nov 12, 2014 12:27 pm EST  Accessed online November 14, 2014  Unnamed company spokesman states that Takata has changed composition of air bag propellant ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 2

3.  “Since 2000, Takata has made more than 100 million inflators …”  “Starting in 2008, more than 17 million cars equipped with its air bags have been recalled …”  Takata uses ammonium nitrate, but two other air bag suppliers (Autoliv and TRW Automotive) use guanidine nitrate which is less volatile. ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 3

4.  “A Takata official, who did not want to be named but spoke on behalf of the company, did not specify how the recipe has changed, but said ammonium nitrate remained a part of the mix. He told Reuters the shift was part of its process of ‘kaizen’ or continual improvement, and the company believed the new composition was safer than the one used before.”  The official also said “There is no admission of a defect with the original version. There has not been any finding that ammonium nitrate or the earlier composition was somehow flawed. We changed the composition in an effort to improve quality.” ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 4

5.  “None of the big three carmakers would confirm that Takata air bags were installed in models that have not been subject to recalls or indicate any problems.”  “A Chrysler spokesman said the automaker has used inflators from multiple sources and with varying designs, and none have caused any problems.” …  The paragraph continues with a direct quote from the Chrysler spokesman “All benefit from robust manufacturing processes and are subject to rigorous daily testing. None has exhibited the failure modes that have prompted current investigations.” ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 5

6.  Read article 1 for more details  Read article 2 – Takata says to add 2 lines at Mexico plant to meet recall needs  Develop Fishbone Diagram for Defective Airbags  Develop Fishbone Diagram for Delayed Recall ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 6

7.  7 Basic (Common) Quality Tools  Process Flow Diagram or Flow Chart  Check sheets (not check lists)  Pareto Chart  Cause-and-Effect Diagram  Scatter Diagram (XY Coordinate Graph)  Histogram  Control Charts  Some engineering / management texts include Designed Experiments as the 8 th basic tool. ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 7

8.  Often associated with Ishikawa’s Fishbone Diagram aka Cause-and-Effect Diagram  4 M’s  Man, Machine, Methods, Materials  6 M’s  Man, Machine, Methods, Materials, Mother Nature (Environment), Measurement ETM 627 Fall 2014Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 8