How could a machinist make a mistake


Assignment task:

You're a member of a self-managed team on a factory assembly line. When you check the team's e-mail, you find this message from the factory's Quality Assurance Manager:

Subject: Holes in Your Heads?

Yesterday in the scrap bin I found a casting with three times too many holes in it. How could a machinist make such a mistake? What's going on?

The answer is simple. The extra holes come not from crazy machinists but from crafty ones. Your team uses old machines that aren't computerized. When you make a part on those machines, you have to drill a test piece first to be sure that the alignment and size of the holes are correct. This testing has to be done every time you set up for a new run. Your team has figured out that you can use less material by reusing the test piece until it resembles Swiss cheese, rather than throwing it away after a single testing. Your team is one of the most efficient in the plant, thanks to creative moves like this one.

Task:  Compose an e-mail response.

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Other Subject: How could a machinist make a mistake
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