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Deepak Gupta my SUCCESS! my CHOICE
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“The caps have flashing. As some of the flash is hard, it can cut consumer’s hand while opening

the bottle. Although the probability is moderate, it is a chance we cannot take.” Explained Paula

without any preamble, the usual Dan-way! She also showed Dan some samples.

Before Dan could respond, Production Manager Rob jumped in, “Apart from the consumer risk,

these flashes are also affecting packing line productivity.”

“Thanks. I understand. What about the bottles? Any issues?” inquired Dan.

“Bottles are within the normal tolerance” replied Paula. “No issues there.”

“Do we know the root cause of the issue Chuck?” Dan asked his Purchasing Manager.

“Not yet. The Supplier is working on it. Replied Chuck. “The earliest we can get the next batch is

after 2 days as all the molding machines are tied up with other products of our company. The deliveries

for those too are tight,” he added.

“What is the potential rejection rate? Can sorting be a solution?” Dan asked.

Reply came from the QA Manager Paula, “80-90% caps are affected in varying degrees. If we sort,

we may probably recover 20-25%, still not enough for completing the Walmart order. Further,

consumer risk may remain as some bad caps may go through manual sorting.”

“So, sorting does not appear to be an option. Any other suggestions? Asked Dan.

Rob was the first to respond, “We evaluated two possible solutions. The first one while an option

theoretically, is not practical. So, let us not talk about it.”

“Second is to manually shave the flash from each cap. This will be very tedious and labor-intensive

job. But is probably the only way to deliver our company commitment.”

“Any other possibilities?” inquired Dan. No one responded.