1

Data Distribution Analysis

There is too much variation in the system, Repair issue varies from 1.7% to 10%. Data shows that more than 75% of the times we were not able to meet the target.

Any data on this side is consider as a defect

a

Analyze

2%

2

a

AnalyzeProbability Plot

Since p -value is less than 0.05, hence the data is not normal. Further analysis must be done to understand the causes to this behavior.

3

a

AnalyzeData Stability Analysis

The RUN chart shows that oscillation exists in the data while there are no Clustering and Trends. This evidently shows that the data is not stable. Hence further analysis must be done to identify

the reasons for non stable behavior.

Process Capability of Issue a

Analyze

4

Current process capability (z) = (Ppk*3)+1.5= (-0.37*3) + 1.5

Z short term = 0.39

5

Time Series Plot for repair issue %

a

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From the Time series Plot, its clearly visible that the percentage repair issue has increased significantly during the end of the month.

6

The quality for Campus is out of control at one instance on 23rd June when the repair issue was 10.13%, need to identify the root cause.

Control Chart for Issue Count

a

Analyze

7

a

AnalyzeBox Plot for Repair issue %

The Box Plot shows the variation is High in overall repair issue with minimum repair issue @ 1.78 % and Maximum repair issue@ 6.25%

8

a

Analyze

The Box Plot shows the variation in the repair issue of Racer is high which is ranging from 2 % to 7 %, whereas, there are some outliers in case of

campus and mostly at the end of the month

Box Plot for Article Type

9

a

AnalyzeDot Plot for Repair issue % of Article Type

The Dot Plot shows the variation in repair issue is High

10

a

Analyze

Issue Count 37 34 34 18 16 16 4021911010798 96 95 65 55

Percent 4 3 3 2 2 2 421 11 10 9 9 9 6 5

Cum % 85 88 91 93 95 9610021 32 4251 61 70 76 81

Issue Category

Oth

er

wro

ng p

lac e

men

t of

st if

fner

notche

s no

t fo

lled

stitc

h leng

t h in

correc

t

poor

eye

stay

stit

c hing/

off cen

tere

d

D- r

ing

brea

kage

stit c

hing

margin<

1.5->2.0

mm

poor

cou

nter

st it

ching ba

ck o

ff c

ent e

red

poor

prin

t ing

loos

e th

read

ten

sion/

exce

ss 1

mm

Poor

Top

line

stitc

h

Stit c

hing

run

off

Nee

dle m

ark.

tong

ue p

laced

3m

m /of

f cen

ter/t o

o long

/ sho

rt

poor

toe

stit

c hing/

off c

ente

red

1000

800

600

400

200

0

100

80

60

40

20

0

Percent

PARETO CHART OF REPAIR ISSUE%

Pareto chart is showing that the Maximum Repairs are due to Poor Toe Stitching which is contributing 21 %

11

a

AnalyzePie Chart for Repair issue Reason contribution

The Pie chart clearly shows that the Maximum Rejection are due to Poor Toe Stitching, Tongue placement, Needle Mark, Stitching Run Off, Poor Top line Stitch

and Loose thread tension

12

Repair issue %

Check top (Thick)&

bottom(less thick,(Material, thread & needle

combination)

Stitching run off

skill improvement

Poor Topline stitch

Machine maintenance

(shuttle & needle

adjustment)

Loose Top Thread/Tight

Bottom thread

loose thread tension/excess

1mm

Wrong top (Thick)& bottom(less thick)thread combination

Machine adjustment should be known to

operator

Materialstongue placed 3mm /off center/too long / short

Centre marking on vamp & tongue

required

skill improvement

Marking from the edge should be

done on tongue

poor toe stitching/off centered

Centre marking required

Machine maintainence &

adjustment

Skill improvement

Six Sigma Fishbone Analysis Diagram

a

Analyze

Needle mark.

skill improvement

Machine maintenance

(shuttle & needle

adjustment)