tX

Chapler 11 I

Process problem solving andimprovement

r Objeclivesl i ' r r lknl ! . , . I r ,1 f ro! L l , . . , 1, . r , , . \ \ ( ) r l ror f r r , .s ' fn) l )1, . , ) r ! ,1\ I1,. ' r ' r l Lr" l , rL^.r jn

' ll ( i ! i . : ! r l ! ,11r( . i r r l ( , f t iJbl( , , i s , ) \ LL l ( ! , -lo I I r r : I | , r L ( , I I r ( . I I r { r j I rh.r(r , ls $ r t l r t r ( i r ' l ( r l ( \ . I I f lL \

o l ' r t , \ i ( l ( , r i r Lrnt l , .* l , i , r r l i , ru. l l j ( \ \ t lk l f ( l r r r i ( lLr( \ , , , r r l t rsrr ll ( ) r I lh r l , ) , ' i , l fn\c5s r t ) r ( \ f i i r { r l

t 11 .1 lntroduct ionl ' r ( r fss i r ) r In, \ ( r r ( ,n ls, I . o l lcn . ( l j i . \ .J l l I { )ut l r sp. f i l iL ol) t0r t r r Ii l i f r . ( orrrn, . l \ . . r lk \ l tn, l )1. , , is , l \ ' r i i { l , i r l i l i (11 of f ( l o l f r i /c( l . \ l ( \ r rs( ! ' r " f r \ ( .Nrr l ( , | t ( , ,1r , 'Lt i .s s l r ( iUl( l l { , . r ( l 1(J th, .Lf( | l i (nr i , l t ( , . rnr !$ l rR In(Jnb(.s l r r f 5 ( lct( , I I i I f (1 t ' \ lhLf $( , f f . r r r . , r ( i ( [ t . r i l ( \1Inr( ,$ l ( r l l t ( t ) l lhc t ' , , \ .sr , r , r l ih, i r r l r i l i { ! l ( ) l . rk( . inr l , , , \ , d, . , , I r ( t r ( i r lIh. l ( , i rnq nrLrsl lh{Jr b. P,1, \ , r ler l t r i lh g(r \ l l { r i ,1{ rsh i I rn( l l l ( . i r l r ll ( ! ) ls i ( , l . r ( l (k lh{ l ( i l r

l i \ esini t r l i . rh l ( . nr((h1,Js, ( r l f t i t . r t . r \ ( t r . r l r l { .n\ rn)nnxI l l ( ) r h!Drb,rs.( l f f (n)LJn s(,1\ fg. . rnr l r ( ! r l i r i r r r l (J inpn^f1rsi .gs\ : t ( ,nr . r l i .n\1rn( lLrs, lh( nc\ r f . r ! l in i { i r r f r l \ .nrrr t . \ r l ( r t f l , rn,do,rh(tk. . r r t \ ! iL l1. ..n! i$( \ l l h is rptro.r .h r l fnr . rnr ls th. R.r l l inr( nr , rnngcfx ' | t ( , i Jnt , t , rnd.r t i (Ds(!r pr i fosses inputs, .onf l ) lsrr r .s( i r r r .$. nol .utputr . l ts i l lr f ( } r i11 i ( h inSe in th! lnng!.gf of m.rn! ( r r . rn i /ntnnrs f f r rn pfr .eni iH.

tI 2/8 Stat s l ca process Contro

1j i : I t , . : l j* prtm( .prL'd,! r, ,nd nu,,,D(.r o, crr i i \ . {, . r/o, (. . .?rcut n7. r ni . t rmJrp mu5r \h.rnqe from rh,. r f . rJ i l r^rr .r t . rppr,rJL h , , r t f r l: . : l -

l r ]p . |e, i r i , ,h, ,n rhef, . rre no p,ohi"m..md no fr .rrh.r impr re. Th(.Jr i \ in8 for j . . tor l lx. wrl t be rh. n, . d ror bcLLer

'nrem.LInd e\renrr i r \ tompr \rhn,r , t ron le\ c l . . whirh l \ i t t le,rd to thecontinuous improvemcni question, ,Could $,c cio rhe job bctter?,In Chapter I 5omc basic rools ancl techniques ,\,erc brjcfty jntroduccd.q, 'me,t rhc.p.rrr \ pn Lr{ fur in a probtrnr rdent i f i dr i , ,n,rnd \r \ Inr, , rnrc\r .

. rmely t , . rrptr ' . rn.r lv. i \ . , du,e and L.t fe.r . rndt\ . i_ \d rrdi . r_grams and straiification.

l l"."lr:: l):. *: : l l":p r,,nr_,elr,, irp.,he,r Jppri,,rf iun bv th,, |c,!.reunn.r . ru. I r \ h ' f ( , ,n th! pn\e\ \ . Iheirc, ,mmrtm,.nr rr . thr . wr l l bePos

, f

ii

aI 280 Stat ls l cat Process Contfo

. Histo.{/dD absenteeism and arrivat times of trucks during the day.',

Crntrcl chrrt thc movcmeni in currency and weekty d;rnand;f a

Distribution staff hav used p-chads to monitor ihe proportion of delivpr i( . \ shrrh.rre lale dnd prr.ro.rnrt \ -rs 1,, toot Jt comptainr. inv,, t r rnqIn! dr! tnhutron s \ tem. Compuler rnJ ! r _. .nrre

^n(.r , ^ r . i r r \ I , u_edcau.r ;nd effecr rnrt1. i , Jnd hi . l^Brdm. tu , , , t rcsenr crror. In ourpull rom their .cr\ i , c. \4o! inF d\ crr8,, . rnd cu,um , h.rr t . hd\, . imm(nsep.tcnt j , r l 1," imf ' 'or inE fofcc,r .r ing in n .rre,r . inctudinB mdrt, , t ina,demrnd., 'utput, (urrFnct \ dlue dnd r ^ mmoJity Fr.cp_.Those organizations which have madc most pro8ress in implementin,r. ! (umf' , 'n\

-wrdL' .rFpr. ,rch tu.mpr,,vemenl h,r \ e r , .c.rqnr, ,(J dt . rn edrt ;st ,rHethr ls lc i \ ror lhewh, ' lHorBr i / . r t i . ,n RL_tf lct i , r t i t 1, , t r . rdir ior) . i lmanulactlrnng or op.,rations activities means that a window ofoppor_tunify has ben clo:ed. ApplyinS rhe mcthods and techntqeres outsiilcmanuiacturing will mnke ir casicr, not hnrdi,r, b gain maximum benc,fit from an SPC proSrnmme.

Sah's and ,tntktti,tiis (J^c area r,! hich ofien rcsists iraining in SpC on thebr,rs ihat i t i - di f f icul t to JfF[. personnet rn rhr: vrrr t funchL,n ne(J t( ,bc educrteJ rn stc mqrh.,ds for lwo nlrronr.( i ) Th(y n((d t \ , unJershn, l the h. iy thc minuf.rdur inF ind or scr_\rce producrnx fr . ! f \ res i l l rhfrr urdnniznt i , ,n5 h

' y l . Ihr{en.rbl

:tt2Sr xPrncrss t roble r s0 r n! r rd rDr. !e nrnt

l r ( f r , r ( l f r ( r r .cminl t lh! . f , rst . f r .sf f t i f { l t I t t | r ! t i . r l t ! nr .n.( \ ( , i rh.s.

N 11.2 Parelo ana lysisl r r r r , r f \ rh j , jL. . \ . , I t ) l I 1( .s( . t i , r ( l l l , . , t r j r ( js t t , l t , , r r t , , (n, lL, | , , I i \ .l r ( i f i , r r ( \ \ ( )1 l l i . sL)r r ( . : . lh( . l l , r l i , r , r . ( i f , ( ) r j i r l \ l l , ( \ l ( , l ' , i r ( , t ( i Lr : , r lI

' r ' . ( i f ( i . | l n lnr i l r ' . r f f r i , r t r \ l l l i , . , l , . l r l l r r i i t ! r t , l nL, i l t l r i r h i .

( ( ! r r l r \ , r l l l r . lu i r ( ' l l r ( ( i r r l r \ l l . . [ 's . \ . ( l ] l r , r l S()(r l ) l ! . r f . r t ( ) rl l , r l r 's s( . , l l l , , r \ i r l ln l r r . ( l i , l l l r : l r l r , r ( i ! r l ( ) r l l r . l \ j t ,Lr l , r t r ( f r / \\ | r i l , i , ( l ! l r l , r l ( ) I l r , r \ l \ r r r l ( ) r r I ( l .nr l r i i . , r \ t , ) l t I Lr( . rn l i . r I \( ,1h, r . ! l \ l r ' r . \ , rnf l ( . . r i ) t r . ,L r t t , r t l r ( L l , . i ( \ t :s t t r [ \ . ]nf , , 1rlnr( i ! , r r , l l l i f ( , r rcts; i l ) f r . r Lr . r i l i ) l l ! ( ( ! j r f l , r j r t rL l j ! | r , rLt . r r ) i r l )l \ ' r ( i r r l I ' l l ! rUsLr 'nr(rs lh(- . ( . r i \ . r \ . r l { r r \h,r \ ( . i \ !1) l i .hr(^ i r i i :t ! '11 () l l , , ( .1( i r | . rh ( , r l ln r io . t l r r l ,

lh r , \ l , r r , l rk, L, l , i f , r l iLrrq ( l r l f . , ( ( ( ) r ( l r i t L( , f f i ( ) , i l \ , ) r nr l r , r t . r , r ( ( ., ' f ( l l ! t , r r t i l l ( i , r1)ni l r l , , , r ! i \ i , i ! l r , r i r ( \ \ ( i f t i : r , r .LI Jr , I ( l , i r r r r l \ \ r :l l r s is . r i ( i r i , i l fnrr \ lL, ,L t r r i , l r i \ f , , i ( l i l \ t ( , r (1, , , , { , ( , , rc l \ L, , rL l , . l

:1, \ r l . ! i ( l \ { r \L l i ( \ i i \ ( l ' , i r . l , iLI j . r i r r , I I \ t ' iL l r , r l . , . , ,L L{t l t , \ t t r r \L\( \l , \ | | i r I ) | ( , \ ( |

'

r ( , I r I l , iD\ , 1, , \ r , l l r ' ( ( i f ( l r i r r l ,1\ l l l ! , t ( \ l I r r r ( 1 i . , 'l r r ( , , , , r l r I j r I , r I r r ( , I r i , r I 1, i I l rc i , ( I \ . , , r1 i ( ) I l ( j r j ( , r r l l \ [ ,L I r ' ,L.r l l \ i I j f , j r . l, l r l t , r ( i l , l { | rs, I r | ( . ! t , r l r l i \ r i r js t i ( ) r l l , , t ( ! . , r ( i j ( r l

Pareto analysis proced r t rcsl l i ( , f ( , i f ( . , r l \ \ , r \s, i r . , , i \ . r . , t ( \ l \ ( ) l hr \ r r ' \ \ ( I ! , r l r t ! r r l t r , r , ,1t I j ( ,r r i r t f ( \ ( r i r ( ' r rL:Lh(,ru, i r l \ , r ( ' l . i , , rs. l , r (n(* . \ r , r t , , , ' l r l \ , r '$o.1. \ . r l f : .f l ( l , i (hfr , l r l (nr I r , , t ) ! ls . : I j . r r \ : I r , r l l ( , I r ( ) l r l r , , j \ , I r l i t L\()rL(.n( l i ll i (u l l l ( i l r ( , (s l i i (1,( i r r . : i ) l , r ' l l ( , l t ' l r , i r i , l , l . l r .Lt \ ( , l r , , r , . r ,nr t ,L, ,l i l ) l t lL l ! i \ , \s1)r i r . , l . r l . r ( r r l ln r{ , r : . , in: ( ) , i , , l ( l r ( \ (Jr . r (1\(s1, r l t r ( ! lr . l h, . i r i { : , In} ,1\ \ l { ) r f ,N(,r l ( \ l , \ ( l ( .1 | , r ( f ) r \ .LI1l( , ! nrL\1.( l l (Jl f , rn: i r ) , , , , l l j is ( l , j t . r | ) l ( jnr , r l r , r \ : . r r ) r . r ( l 1,rr

l l s( l " r l ( . r ,h\ i , \ r \ l r r t lh() l \ f . \ ( ,1 l f r ( . r ( )n.r \ : . r \ , r r ( , f (N!Llr l , . l i r r . t ( lr ( l ( n l i r \ lh , rc, , ' $ l r ( r nr( iu l ( l nt i \ ( . I r i ( r t \ r l l rLr l i ( )n. ( ) . ( . is 1, . , \ ( lr r r lh i ! \ \ tuur( \ ( ) l f , i (h( . r !s( , ( i l \ r , r f r ' , .N() ,1,r r ( l l | l , (n l r r . r i , L)n\e( l( r r L()s l l t s , .ns(!rr t ,L l ( ) , rs\ |nrr Lh,LL l r (nh t \ l r ,s () l . r . , r \s i \ \ \ i l l tf ( r lL l i f f ( l l l r ' r l .n i i t i r r l i { , . (n lh. , r , )s l l rcLlr t r l r i l \ ( ! i I i r i rg r . . r { r ish(, ' r ld f r l lh l ( l l ] . l t , l , r l nI i rh.r ( ) r r r I l j f , s . r , ] f f ( . (1 , j f ,e, lLr i r in] lf ( \ ! o.k lo 1, . r f r lu.rr i . Ih is nr,r ! h. n.( esnrr \ h) i rnpr( \ . f l , r r t r iNr.rn,rnr()r , r ( \ \ h l ( h ni . rv t ) f . r ( l \ efs. l \ i lJ( , .1.1 l ,v.r h ig l r f ropr)r t i ( in, , t oLr l futl r . n i t r1 l { . t ( \1. , \ r r r l \ \ is usinl t ! , )st . r \ lh( l ) . r \ ls $ i lL b{ nc.rss.r n '

xI 282 Stat ist ical Process Control

tr Table11.1 Dataon batches 01 scrilltagren scrapped/rworkd

SCRIPTAGREEN -APlanl B

Eatches scrapped/reworkedPeriod 05-07 inct.

Balcft No. Reason lor scrap/rework lvlalerial Ptantcosl (t) cost (t)

Labourcosr ( l)

05-00505 01105-018a5 42205 02905-03505-04705-05805-06405-{6605 07605-08105-08605-10405-10705 11105 13205 14005 1500F16805-17005-17805-17905-17905 18905 r9205 20806-00106-00306-01506 {2406 03206 04106 05706 061

500500

4000500

1000500

4000500500500

1000500500500500500500

10004000500500500500500

1000500500

4000s00

1500500

2000500500500

l,4o slure conlefl highExcess rnsoluble malterDyestutf contaminaliofExcess insolLrble mafterLow melltalg pointl,4o sture conlsfl highConvers on process fatureExcess nso ub e ma erExcess insoluble rnatterFxcess nsoluble malterLow me ling poiflMoislure content h ghI\,loislure content hl0hHioh rof contentExcess insoluble malterExcess inso uble matter[,40 slure corlefl highLow melttnq po ntDyeslutf cof laminalionEtcess insolubte matrerExcess nso ub e maller[10 sture conlefl highExcess insoluble matterExcess rnso uble mallerLow rnelt ng pointlvloislure content ht0hlvlo siure conlenl highConvers on process faiureExcess nso ub e mallerPhenolconteni >1%/Vloislure content hrghlJnacceptable appl cationExcess insoluble rnatlerlvloislure content hi0hExcess insoluble ma er

50 100n 125

22000 14000n | 125

500 350050 100

22400 14000nrl 125nrt 125ni 125

500 350050 10050 100nrt 2000n 125nri 12550 100

500 35002200a 14000

ft 125nrt 12550 100n 125ntt 125

500 350050 10050 100

22000 14000nt l 125

1300 200050 100

4000 4000nt 12550 100nit 125

q 0 0o"r" dIt&

Table l1.1 lCont n!ed l

SCFIPTAGBEEN-APlanl E

Bahhes scrapped/reworked

Period 05-07 incl .

Balch No.

06 06106 06!06 0i l0l l 0r806 08206 011406 103|6 l t21t6 l2ill l { i l3 ll l | i t4 i06 15001t 151u0 l1l l01i t1i50{ i t /20{ i I1J006 t9l lori 2020t 2 t , l0/ ' l l l l )0t 0210i 0iliJ0/ 051tT a5/07 0( iut i t t2t i a i l0/ u8204 08/07 09707 l t6AT 117

La00utcosl { t )

1000t00500500

1000100050050(l50050lt

500500

500500500

r000400(l500500

1000500500

r500500

.1000500500

r000500500500

Beason lor scfap/rework

Lr1]er l i l : io l rbh f r i l l f rLxre, i l r r r i r t r rb e rrr i r l l r l

Firosr I rr L bk f;rttrxtKrcliri I r1;r)lLrhk f ;r1lIr

t ln i | (xrolr l i r r Lr , rbsorI l r )

Lf t r* r : iDlrbh fr , r lhr

Lr lxr : is l i0 r l } 0 r)r , r l l0r

l rcLrss f : | r r r Lr r l ld

Dtr , l r l l r .o r r , r r f i r l r rLrcel is rso Lb I r f i l l lorLxreis rso Ll) c f i r l tc i( ;o r !ersron procl lss l i l rL ll icc:s rr1] Lb c i r , l l l lxLxrms i r !o LhI rnr l lLx

l)i.os1ril coxin n,rl orLxoess i rso Lrbh r i r lcr

Excess i fsoluble malterExcess i fsolulr le mri ter

lllalerial Planlcosi ( l ) cosl ( f )

500 350050 10050 t( l0r i 125l l l5

5rlll ll 0500 3!00

r t : !r t2\

5ll I0050 100

ir 12550 100r i 12551r t | ( lbu 100nr 125

5UU i i50022000 ] ]000

l 125| 125

??a\a 1.1000r l 125r l l f5

1300 20005U 100

??t0a 14000rr 12550 100

500 350050 100n 125| 125

lCont nuedl

xI 284 Srat st ca Process Contro

'at Table 11.1 lConl inued)

SCRIPTAGREEN -

APlanl B

Balches scrappedleworkedPeriod 05-07 incl.

Batch No. Reason tor scmp/rowo* Malerial Plantcost {f) cosr (!)

La00utcosl (t)

07- i1807-12107 13107 13807 15307-15907-16207-168a7-17407-17807-18507 19507-197

5001000500500500

1000500500s00500500500500

nrs00nt

50500nrl50nr50

1750nt l50

12535002000125100

3500125100

1002250125100

Excess insoluble malterLow me lino poirtHigh rron contentExcess nsolub e mallsrl /osture conlef l highLow rnelting pointExcess nso ub e mallerl1/loislure conlenl highExcess insoluble materllloisture content highllnacceplab e chromatoSramExcess nsoluble malleri,lo sturc contenl high

derivo ih.'grcatcst finnnci.rt benffit from thc (,ffort (,xrted. We shall usoa generaliz.rble stcpwisc proccdLrre k) perforn both of ihosc rnatyses.

Step 1: List all the elementsThis list sh(Nkl b: etauslivl b prcctude the inadvertcnt drawinS ofnappropfiato conctusions. In rhjs cnso the reasons rnay bc lisred as rheyocclrr in T.rble 11.1. Ttrey are moistufc contenr high, cxcess insolublemailL rdve. luf fconrJrnrnnri . ,n low mFtr i , rr p, , i . r r , onver. i , r , pro. er_ Lr i ,un,hr{h rr^ i (orr l . nt . fhcni, l r^rr tent ' ner L.nt. ur. , ( ,enr.rNc.rpptr. . rr i , ,n'Dir . .enr,rD e.rbnrpinn .J,e{ i run . n. ! jepl .ro.e. hrom,rh,srdnl

Step 2r lVeasure the elementsIt is essential to use thc samc unit ofmeasure for cach elcment. Itmay bein cash value, time, fn:quency, nunber of amotlrtt depending on the eLmcnt. ln ihe scrap and rcwork case, ihe elemenrs

- reasons may b measured-in tems of frequcnc)t iaboul cost, material cost, plant co;t and totalcost. We sha use the firstand thetast turquen y and totalcost. The tallvchart, trcquency disrribution and cost catfttations are shown in Tabte 11.2.

Table 11,2 FcqJsf:r 'd str bula1 anc .a1a , !s1 ! i r r :s lL:1 LhJtclr : ; sa at! i t f9. ; ! r .kaa

Beason lor scrap/rework Taly Freq Lrncy Cost per balch (t) Tolal cosl i l )

Ercess nso Jh e qratta,Dleslr lJ conlam 1alrrLo\,r melt nq nc.r tL0lr , le iS Cl ! r0a:Sl lJ : faH !h r .on aont. 'n:

Llnaccepiab e a!p a31 rfLlnac.eplab r a.sc. l r i .n sfe: i rnrl l lacceplal ] ie ch' !ratL.r i r

23:2l

t '

";

?22

I

65. ilt25

t,'t"..ia".i100

.1:0t0:5i l iJ5"nil

lL iaa095!

J5LII

149502000c

160i]0055000

r2t0i l050009600

10000950

1500

t tX 286 Srar st .at proLe!s to t ro

Step 3 Rank the e ements_lh

s , ) rn. f i rq t . r l .s f l . r ( r , . . r . r (J i fg 11, rh, , t r rusI i$ nr i r t for r f r t .s!r-i i , . r l , r r Ih i \ i , rh( . (nr j . r l ( t i i t r , r , r . . h. t t r r ( ! r , r t , , | . l tJ ( t i l l r ibLir i ( ! ,, ' , , ( l l l r ( . i ,su,r l r \ t ( . r ( \ ( l i \ l f i l ,Lr t , , , j . l r ( t i \ f . r f t i .u l r fh. r r r f ( , r r , l r ri , , , I ' ! r r ( , r ( , r l l \ r l f \srJ i , \1 ( , t ( .n j . r r l \ t i , , ( , \ , r i r r t i ( , . t i rLr1, , 11] , , ,* . , .l l l .n) | r f , r i r$ r I \ .1$i ! n l t t l ( \ l ! . r r \ . . , | ! t t , . , , .LtJ Llrsrr jbI i i ,n, j I L, ,l r ( . r , , , | . ( l , r l f , ) | l , j r ( ! r ! l t js l t ) . t r { j r t i . . t r i t ) j r l i ( ) f ! r , f ( jnt , . i \ i nL ( i f r f , , \ l r j i t r , r r l , , ( j | $ j l I th( . l , .L l | , r jL \ ( t i \1, i l r t , r j . , r rk. tL j j . , t h\ c lL.nrdj i y,r l , ( , I r l | , ( , t ' , r .1() , l r . j , r ! ( ! t h\ r l r ( . , r f . r { rL( , I t \ . , rLr( \ , , , j t tk

| ' ( ! tLr l ty r l r : rn l r r r r ' r r n i , r r ! rkrr ll )y. , rur i .1t ' r . I l l r , Ffr ' r r , , l :Jnb'rL ' . r nr I r ( tLJ.rV r t r r i , r ror or lJr ! tLr i ! ry

ri

17 1r1 r ! .1r I t . ' r , l | , j t ) l t ) ?1 u\ 2a 1t- : , : \H r / . i r , t . i (n i )

Fiqnm rr 2 I

ro f ( . rLr j r l l r j ( ,s( . r . r | , r . ( t ( ,sort ( , rs( . t , i Ih. I t str r \ \s l t ! , I . rs( ! r rf . r . l ( \ l , r . . , j , ( l I1t l , j i11\ tu. | ( ! ( ) i , ! . l |D(, | ( r . . $hi tsr Lrht( . I I r , jsl l r ( nr r , ) r ( i . r ( i l t l r ( ( , , rs i I , t . t ,s l

Step 4 Cfealc irum{t attve d stf ibul 0lslh( r , , r : .s. , (UnI , j l ( r l t r j , j r th. t ) i . ! ln\L , , I r t , \ i l , ) rhf l { )s( . \ l . . r l( . , r (nrr ILr l , j l r \ ( , l ] ! ( tLr(1rL. i :h&r,rs,r1r,r . r r . r"e,r r t j ( , r { j l . j t . t . t r ( . . t0n

' ' '1 . . , . , . , , . . " . 1 , , .1 , r . . . . , , . , t , . t . .r l { . , I I \ . 1, . , . r , . , ' . , . , . , r , " . , r , t r . . . \ i . r . , t .

r , ' t f . r l ! ( nL \ ' o l ( ' . .Lr f f (J j . f . rnd n) i . r t r . ( )sr , l r ,sf \ , .1] \ .1\ . the i r r | ( , l1.r . l

lh i r rg ni r lnr .nr l r f r , jbout thr .u lL nt i \ . ( !erJkIr L l rst Lrur i (n is rh.rrLh. gi fs bets.( n .n, h r ' luD.f l rh( iutr t bc.{ tu.r t . t l rh. ! .11, Ior , I r fn . r .' r1 l , . r , . . . l , . r t . , , , . . . r . . , . . , , . t t , . r , . . ,nron

' I r : t , rkr i , t ( ) .o|hr\ f t t r , f f . r l r t r Ic! ,o i r r i ,n\Lrf . wi th ( , l { !ncnt\ .

Proress pr0b cor so v n{r and npr0,rement 2E7 K

Table11.3 Scrap/re$ofk Pareto analysis 0f l reqLency oi reasons

Reason lor scrap/rework Frequency Cumulal ivefiequency

Percenlaqe0l tolal

Lrress i ro rbe fr t ln

DvrslLr{ l r r ! i n inar i InCorvcf r r r r t r or l rs I r i j r ro

Al) ! ) r l ) lo l r i tedrr l i

Lr ! fs l r 1 l r I r l i r r i r ,1 l r r rCofrrrs rn t ) r r lsr i Lr L rr l

Fr,rsr i r ! .1 rbh n;rr ior

l l r i r r i t r i r l l lo , r tp l l i ( r l

Llrilclrf lrlr N Lrr onrirl0rlrilrrrt ln i rcrPftr t ) N r l r : ror I l ur

322J

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117 509N /!

100 00

Talr le 11.4 Sa rt / rc!r0rk Pir fc lr)r r iL lysi : io l tot i r lcosls

Beason lor scrap/rewofi Tolalcosl Cumulal ivecosl Cumulal ivepercenlage 0lqrand lolal

r600Ll0t2!1100b500rl200ll01.19501000096005000450r)

l i0001l2llt0t0i I l t0 lr0lJt5!1r0

3l l9t !r)il1)tt5l:99050100000

,1ll 1l71t 033 7588 75925950il7

'l!8 6591t 75

100 0

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tf:& reg srrr sr cr prr .c!s f tnnlro

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l l i ( * ( . r ( r , l r t r , , . r l ( ! l11, , . ' \ ' l ! .1, , i f l r ( \ i t , l ( r r i , ( l , l r , i \L h(,rl r ! r l r1tr l ,1 l lL,r . l r \ i , . rL l , . i l L) f | :L( L( ,1( . , l r , r , i l l l r , . , , l , , rLr \ ( . .1, , r . ( l rLL( rrr l \ l ln r( t , i l i | | r I r | | r , ) r r r r r r I r ' i . tL( t ,1, I ) i t ) |1\ l \ ( rl r , r ) t l r l r r , l i , : r \ ( i r , \ l , i r r \ r r , r l r r ( , \ | iLr l ) , r l t rL. . 1 l r . r ( j . .1. , ,1\r , r l ) l j r r i iL i ! ( l i , , ( l j . , l t r , r ( , r r , , , lL\ t . \ \ ( . r \ l . , f 5 j i r r i , \ . , i , rL( . r il r , i l r ( , r ' ( ! r ih( . I rL i rL. , , ( ) l i \ ( ( , :s | .L, l r l r l , , . i t tL, t r i l l l , i \ , r1,( . l j i11t- lL l j ( \ l r , i ( ! , t , ! l r ' f r I [ , ( ' r l i , rLt rL\ s l r ( ] r rL\ tLr i rL l ( r l I r i r \ r r i ! \ l

l l ' ( ( ) r \L!r1(n, l l ( ' jLr f l l jL. , , , L,1, . ! l \ ( l \ , l ( l i r . r ( I j r i r r j r j t t l r sLrt ! | , r r r l

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' I a . | , , I I . , , . | | . , ( r t , r . , r . , , i .

r r ra , r . l . . . i l r srr , . . . , . , . r , , t , , / r1r . . r , . . . . , , r . . , . . r . . rt l ' i \ l . .hnir lLr f , \ l lC nnr lvsis.

Procedufal n ote, \ tJ( { ) r t ' , r r , lo,rn.r t rs is i \n l1\ \ ,ofLr l ,n.r ( t r ! i fg ( t ( t r ! f , t ( \ ) t b l r l i t i \L,rr . ( i ( r r . I rp i r i .n l rLr les nhich l rnvr n(, I r . r thonr i l i ( , r t [ \ ] ( t , r i i , ! r . t lshrr r l . r l r , r rs l . r renr,nrt 'ckr t , \ \ ,h.n Lrsir)q rhc.(rr( . ( . I t , r l r , r l i t is r r ) l

l . ' ] , r . " i t , . i . , , i , . t i . 1. . ,J , r , , . , . r r , . . . , , . , r1| i , , . , ' , , 1, , r r r l , , . . r , . t r . , , , t , , , r . .1. , , r t , t , , , t , . ,| 1. , , t . , , , , , , , t . t , t , , , , r , , , t . . , , , , t r t " r . , t . , r , , , r , r1, , . , r

r lar , ' . \ . .11\ , ' i l \ I . l l . r i , . r , t t . . ' , . , . t , , , . . , . , , r , , r . , r , t . j ,i f l i l h, . , l ( ) , r f strr j rh l r \ \ ' . r \ ' t l j f , r inr ( j t t t ) ( , t , . r |1, t ( ) t . .hni( tLr( , i r s in, t , l t .

l ( ' , , fsr , . l l r , r l ihr nrr \ i rLrnr rerrnl rs r . rUr.r( l tof I r . .11() f l ( , \ t ( , l l { \1,LrLr l t r : r r , l , r r r ( t I r f ( , r ) r ( f r ( i l t lxs!sr( ! | . r t iL.rpl f ( i , r .h l l j . r t . !nr . r l , , f , rsi l ! 5() l \ . { l f |1,1,1( nr\ nrLrst b, , n.rdf to t r , r i t UI t i t thc t r r l t , r (nx,s t r . ru.

r 11.3 Cause and el lect analysisInr , i \s lu( l , " , , l , r t , r ( i t )knr,1l j . , . / r1r s( !h,rs,r tnr l i (ut . r f r t r l . ( l ( , . , r . ( . rr rL pf( \ r 'ss i , r l \ ' lnr t r l l . ( , I r ! .nr j ( t . l t (1t r i . r l , "s js In,rr1 ' r . , ,11. , , , r1 1, . - , r l , , i , r l . ' r t r , . t r . r , , . , , r . , , , t r l , , . . t , , .1lh \ l f (hnlLlr( . ( ( ,nr l ) r in\ usr i f ( ) l ( . r r is( , , r f ( l L, [ , \ t , l j , rsJ. ! r js . I ] ( l

lhr(nu!.rnLlc l l ( ! t ( l i . r i t f , l r i rs() t t ( , rnr fnr j ( r r \ t I f . rssirr I , r5, i r r , ( ) i thr .l ( \ l l r i ! l rks , r l r l l , \ r l l , r l i t ! ( iR.k s Wlr i ts l rh i ( \ r . r i , ,nrrrr is ln( , , i t is , r n)rnt \11( s\ l \ | f r i i I I i f i ls sL()} l , { i l t | ] t , nfpl( l l i ,n, ( ) i th is nr()s l usehrt . rn( l\ f rs. ' l ik l ( \ ,1 l ln . , I rsr JnJ.J1, . .1 ! i rngr.rnr, . t ! ) t r r \ \ .11i \ t lx , tstr ik. \ \ , . rL lLrgf . r f r ( , r l l ( r rc i f \ f fk, r ) , ( ! thr f ishh!r . ( l i ,1:rnrI ( . r l icr rs r tp. i fnrr .J, sh' \ \s th. . lh! t , ) l t lx l l l r , l ( ) i . r .enrf . r l 'spirxr s.r th lhr . . ruses.rrt | t ,enLls( i l thc ' f ibs 'hhr. l rL,r .n.h f r1) r i r lhctr . rs( nnnr isshotr ,n inl iguf . l l .5 lhe pr incip. l l . rh 's l isn\ i i i rst nnr l r t rJrr .Ju(rc l t i r thei fsutr-( . r rsfs, . r1\Ub srLb ( f rscs Inrr .ss.ry lh is pR)(,ss's

ro. t f r recl unt i l i l l lhc.(nr r i \ .b le.xLrses h. \ e b. 'd inctLrdr,c l .

Ihc l . . tors . rn, ih. f ct i t i .n l lv .n. l |sed in l ight lJ i their tmbnble.(ntr jbut io. to the cthrt . The l . r .nrs selc. tccl rs nrost l ikel ! c.Uses of thc' ' r , . , . , rer , . r . , 1 ' . l . r t , , l , . rn, r . , i , .n t . . i , , . . f r r , , , r , , - , l , , i r , . , r

.r,Pr0cess prob em s0 ! , nq and mtrolemenl 291 X

Fi4rE11 5 B I n l , l l l

lh( f f s, l , r r i ( , r l l r s , r r , r l \ I t , r l f , ( r r \ \ is n l , i l ( r l , , , r r i l 11, , 1, , , . , fL,s.s

C0nstr l rct in0 the 0arsc anr l ef fcct d a0ram. \ l i . ' \ . l r lL. l l r , . l lL, , , , , l l ln,J, i i , r l , i l . ( l l ,1 l r , r i , t , r ' i \ l \ t t t t t t t ) i r i t t t i i ,r l , i . , s f i \ l l ( , lJ , i , i l r i , l r , i \ ,nr (nL,\ (s, i , ,1 I r l , i lh, , i t \ ' , i \ ( , , ,u1, , ) it \ t I ) . i ,1r l \ , \ ( l i , , , ig i , rg ,1 . rs hr i , r r , r $ n,r i l \ , r r r L r lhr s i . r ' . , 1, , t , i , ) l li1 , , , . , ( ) \ i r r ! ! \ l ( l t l , . r \ , r ( $. l t r inrr( l , rnt l \ , r l ( l , i ( i l i , r

. , r : . ( r i l ( i :d, , i l

! i ( l L! . is , rnt \ , , , , r i l lL\ l ( lL, , i r rgr l ) r . i i , i \ l ( r rn in i tsc\ : i , ) r l i ) ( ) l r l , r i , r l i ! ,! r . r l ( : t , f { , l ls l r (nrr t l i . \ .ss i ,nr , r l l , , i . , , i l \ ' , : ( ,1 Ll i , ! r , r t ) . .1 i , , r ( l t , , r l rl \ r l ( , , \ r r l \ . r r l J l l i , l . . r : ( i l l f r . (1 .u. r r ( or l r r l ld sul i :L! r r . r i l . I r . r l \ s !

I I r ( , ( r I r s I r L | ! { i ( ! r ( ) | r ,Ju:( J i rLI L l l f ! t { l i f ! r . r r i : ! \ t u: l r . r1f( l $ l l r

l l l l , r ( r1u, l i r r r iJrL,r0i , i . ,1r . , l \ i ! , , in, ,u ln(1rf , is l i , , rs. , \ r \ l , . , j i . l \( ( ) r j ( . r , r . r ln l \ )u l lhL.r i i ( ) r , , t ( ,1 *n\Ln!.( ,1 t ( ! ,* l i l ( l ,$,rsLnI in{ I ' l , i ( .r \ s lu( l \ ' ! l r ( ) rLf l r r ( l lu,r i ! l rLf l ( ) i r i \ fn iur t . t l ! t ) ,oL, . r l ,ut l r . r ( ll r i (1. l i l l l ( f f ( ' t f ( sr . , \ 'er , r t1( , r : ( , ! ( r r l r r . f l i f {s. lhL lJ( f . ( ) l f r ( ) ! f ( \ rs is r l l f i l ru l ( \ l l ( i , r t { ) | r ) I ) i r r , i I i ( , I r ( ) l l ( \ ) nr( h tJ l l , r r f $ i \ i r i l t r r ( lsh 'u l i f t ( l .srr lv l ) i , r l : \nr fn 'nr !L) l r f ( ! r s\s l ( , i r , r l i , . r f f r ( i . r l l r lh{f rot) l ( ! r t r r : l r r r r l t t l t t ' r r r \ ! l \ r f t \ ) i f l1\ l r i . r r t { rn, . , i l t r r i , i . . Nlr()Lrs{\ l lh, t r ) l l ( i$ i rA st . f t r is{ rp}) f ( , . r l r

Step 1: ldeftify the ffectl l r is sorLnJs sinrpI fnor] i t l r bot , n i , r . l , is o i ler l 5( i fo( i f \ ! lon. thntnuch t inreisr \ .s l { l i . the l . r t r f s le|s ol thr l ) rJc(\s l l i : \ l l i l thnL Lhc( ' f l r . l of I f { ib l ( m is s l . tc( l in f l r i f , . ( in.Lsf i ( , f f r in( i l , )g\ . I h \ t r i l l h, , l t

?sX rg: srat s l ca proccss conlro

h' r \ o id thr s i tunl ion N hcfe th. ' .aIsr .s ' nrc idenr i f icd afd r l iminated,orn\ to i i fd th.r t thc 'proble|r 'sr i e\ ists. tn rhf tcn b.S ronrpni \ , thect t r ! t (1rs r l . i i f rd .s 'W.slc Lrrr f r ro lcr fd l { \ r ! rnsnl t dInn{ t l r . te. lbrgnr i f l . r . t ! f r ' I i f ic(rs l . t f lncntss! .hrs rhisrn.r \ t r ( ,nfr i \ fd r t ! . nn'rrnrherol f t , ! t (s,Lnrt thrm,)st . ( rnnrorrnrfronso|sus()hlnin. l rhf( j Iq l lbf . ' i r \ lof l r lng, onc of lhe' \ i t , r l L\ \ , ' { , | ] i pn1(, J i rgr . rnr, . i rk l soUr.csr)uls i { l ( ' l lx f r r l | . t i ( ) f { l ( f . l lnr . f r

Slep 2 Establish goa sI hr inr t \ ) r l , r f .e oi fst , rb l is l r i I t rcnl ist t . , IncnI i | ! l I t { ( ! r ts , r r rhc ({rr , . l( ) r I i \ fnnr l . I i s( ,1\ in{ f ( l \ i r ! , f I r r ) t b. (^. f ( .DI l r . js j1.d I ' , ( ) i ) l , .nr\ i \ I r f l is r i , ) t r sr . l i f r t r , t | . r l in" . i r t . . )v{) | f M,,s l lu) t l ( . n.{r t t r ,l , r \ ! t l r , r l l l r ( . i r .1t( ! . ts . . . r ( t r re\ i I i t s , , I r . g( ! r l rn 1,r , t . f t , ! f l t j . r l j l ( ,, r ) , i t i r i rk t , , l r ! i i . f . r . / \ r1, , r t st t r l l , t , r t j . r f i ( ! r . . h, .s l , ) t ( \ t L j , s. I j .r ( . f , rs. i nr . , r : r , . r jk ! r t ,1, t , r t , r t t , j r t r , fnJlr t , . , , j . I r ( t th i \ n jUst in. tL, ! tc, ll inr . l r i r i l In l l i . l { , r | , r ! i i f r r r . t lx !o.r t r ! , rs, , r :0|{ . r , f I l r . { t r , . t i1, I i r l\ ! . ' \ t ( , in o rh, i lh! ' l l r is r ( ! t I i r rs, , ) l ( r , r r \ . , . r 1fr ! t UI( t . f s l in( t l r | , ll l ! \ i l rL.r l io,r f r i ( ) f l ( i { l l j r r l t l lx , i ( , . r1 l rs | ( \ ( .s\ , ! \ to.stnLJl is l r t t tl r rsf l r r in , ) r { l ( f l r i k I ( \ \ , l ( , r e\ . I I t ( . . h l l , | , r 5() t ( , f { i1r l r ( \ lLr( t i r ! rl r . 's l \ \ ! r , ' ( l i i ( , \ ( \ l l l i . t . , rs,rs l , ,s, , r : ,L, , I j t r \ t r t t l { r r ( .nt( , t i ( ! j Is , r l l ., r l l l r . . ( i rnrrur ( r f (1r l ( ) l th lJ i , , i ( ! I

SLcp 3: C0nstruct the diaqfam frantewOrkI hr l r . | 'k \ i , ) f t ( i I s h i . l i l l r , . , rLrscs. . i r ) hr t is le(1 . rh t r , , v. fv h. l f lLr l1, , l l i . ( r ( . r lL\( . t l r l lk inL t , r ( r r 'ss t [ , , ! r thor ] r , rs l , ! , . ( l l tk l ! . ( , t lh( ,lL\e ' l 's (J l J) f , , r l r ( t iof n, .n. l l f lncnt, \ { . f ! rs. l rL l i . lhe!(rrsrr , ( . r ( ) | ( ) l( , r ' , \e. r l . l l , \ l r l i , igf , ln\ lh, t \ . { ( ) I r l ) , ! r ( r , rs{) t rn\ ( , t \J. . r l i (n, j 1. , ,k

lh\ l rk l . i . . Lr( l i r l t 5er\ i . .s , nr . rn, f i . r ts, l r r l . I rV

I 'n\ .sscs or nr( lh( t r ls . t t f . rnsl()rn,r t i , ) , r .l ' l , rn l , c l lx bLr i l ( l i r iB rn(](quiprD,, f ll l ( ) { f . rn l ( s ()r l inrc i . r l r l \ l r r ( ip. f , r l i0rrsl l ! ) } ]1, , , oper.rk)N, s ln i t . rn{ ] nr . rn.rg(, fs

l l rcsf f f r f lnr .J (D thc r)r . r i . r ibs ol rh( ,dt . r i j r r , , r(nr l ( ) t thr 5pi l r . r ) l lhc dingfnrn (Figurc I t .6) . I hr.nus.s u.dfr th, I vo '1" h(\rdings.. rn Lro vr t rLrbtc

\ ! l th th. c[ i ( , . t r t thcgr-( ,upi ,rg or thf ! rrbr l r suDs( ( lLrL'nr rrLt tv

'S. f Lo.L! f , , K.(1. , M!hlcnunf, A Jt , ar)d Oikt inr l . l .S f t99:) nr / , r r r r , , r , j{ ) t r r r lors Mdtr , r ! . rdr t , r r I dn, I r ihnin, Lond(ni , t ,N.

p r t r I nr \f iqtrrc11 6 rr i , i , . r ! r r f n| r r r 1, .

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i , \1\ . r , | | , r , ' \ t , r rL r | | l r t )L, l t l l \ . , ! , l t t l j , ,s t \ ( 1, . ,1 l r ' i ( .1.r , ( , ,1nr l ' l | l \ \ , \ , r ( t ,L,r i i r r ( l ( , r ' i r l i l r | . l j ( ( ! r . , , , ,1 i l r . , \ 1r . , , l ( \ [ r ll ) \ t ) l l r ' , r , r ( l t ' r . . l r L l r t ,n , r \ l r r i : l . r r t - j j i , , fL . . t )1,1, . . i , . , l i1 l ,L , l \ . : . t l

l \ ' rL\ lLr in\ l nr ' ( ,LL, l ( L, l l , t ( , , r ( (

3! 11.5 St lat i f icat ionl l j i ! i . , l l ! . . , r r l , l ( . . . t l t rL(r , , , ,L l l ! r i ! ! \ ls l r IL l ! , r l r , lL t r , l 'L , r , rL.r , rt , . : i | , rL l ( L, l , ( ) r , , ,1, , r r1,11.\ ! . r , , j . l r j1. , , . , ,1 , t r , | , j ( t r ' rLrLr( \ . , . ,1 , ( . i1, j , , .r r ( ) , r ( . . i , ! r . , ,LL.r . \ . , \ l r i , . r l i ,nr i l i ( \ .1,r :L\ l l r ! , I | f t nI . l ht \ ( \

t r (1, \ L l , , rn, , r l , r l \ ) r lL i i \ \ \ l r r \ l r (1,( \ r r l I | r ( . | r r rL(rLIr ( , L lh

51r,r1lr l ( i l i ( ,n, , lL(1, , \ , i l \L\ \ r t , \ ( ( , l l { \ t ,gL)r (1r \ i r l l l i r , r \ ' l t ' l L l i t . ir r l t j r r r ( . r r1 rr i t l l 1tr)Li l \ l l t , i . l t r \ . ( l l ( ) ! rL i r l { , l r . . l r L( i r i r l . in,r l t , .

s |L 1l

r \ l r , , l I r t r l r ) iL l j ( . . ] ( Lr( t r j , t ) l l t , r l r , | | i . r rL l . . , . r1( L l , r : i r , | | . . I .] , '

, r , l " t ,

, . . Lrr ( , . . . | l l r r . , r i i ! , I t r ( \ t ! f r . . t i f . i ( j r I jL. iL r t rLr L l t - . \ i . r .1i r LrL. l r ( , r t r . r I1rr ) t | .LrrL. l t r . : t r j r t \ j1t r r . , . , l ro l t r ( . l l l! t , , , , l i i r I t l Lt , r1! r , L l r . i r j | r , r j . . r t \ ) .1tr . I r , t1Ltr . . l j ( t i | , t r , . r r r , i , \ r . . .rL i r r r r t I . . I I j , I I r \ L . I L , | , j \ j t \1, , , . , r , t r t , , , r r r l t l , \ t . r .

"'1'l, r i l l l

$l r i i , , , . l l r lL, \ \ :1t , , . , , t r rLt , r , i j , ) , ,1. l , l j . . j r t , t r . ln, . , . , , , r , t r r . r t r . .r i . t f \ r : l i ( |1 I r ( r t . \1|LrL.r i ( rLr , j l1\ t ( ' r l l l , t r lLr , t . , l r ) , t , r1 i . I r j r . I, r i l l r ( L l i l I , r ( . I ,L jLIL.LI

. r i ( t l t r ( iL. . . t t r r . . t , i t | | , ,L, i i ( . r t L) | t iLr t t r ( .1 l , r l , . , r ' . .1, , , r i1 L. , t , r ( . r , i , t , , ! l i , l . , r t , , i L1, i ( . j t rdr . . ! ( ( , r t ,L. \ rL

1i

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lilt

l*ii*lif,,:l rv( i r l rn i r l

I q(e l l 13 a .Lr l r 11, I r r r r ii , i , r , r l r , r r l l r i in ) , / I

'11, " I dtrrr

() i . , ) r r { , l ln r l \ t fs( r r r r \ l r ( ' l r t (

. r r l l lo l lL\ l i r i ! l i l r r ( r r l ( t ) l , , rLrs ( ,1l )n.1,11i(rrs.r f . r f l r r r r . ' l

: , i l | l .L l , r l , r s l r ( 'u l ( l t ) ( [ ( t ) l l ( ]1 lLh( 'srNL,( ' l \ 1, , r l rqLI , r l l l \ 'ssLlr l r Lrr l , ,

{ i 11 .6T

Summarizing problem solving andimDlovement

l l s . le i r l l )n t l re rr . rnrp[s t reserr t t \ l i . lhL\ .hIPnr lh. ] t lh. fnn. ip lcs rnd ( \ t f i ( tues of Pf tnr l ( rn:ol \ i ru nnLl i rnPr( i \ .nr f r rL nr.r l rc.rppl iq l i { ) i . \ ' huur.rn nclLvi t \ ' , pr^ i !1.d lh.r l j l Ls r l gxdf( l . rs,r Pn\.ss.lhe o. l \ ' \ \1r \ nr co. l ( ) l Pn{css otr tpL, ls, \h. t l r ' r t l r r ' ! l ) f i r l { t . r ( ts,

xI 302 Stat istrcat Process Contro/

paperwork, snices or communications/ is to nranage the inpLrts sys-tematicalll Data from thc olriputs, the proccss itsclf, or the inputs, inthe for of nrmbcrs or information, may thcn bc used io modify andimprove thc operdtiolr.

I'rcsonting.lata in arr cfficient and easy to unc:terstand mnnn.'r is.tsvita l in thc oificc as it is on the f.rctory floor and, as we have seen in thischnpter some of the basic tools of SPC and problem soh ing h.rre agre.rt dedl to offer h all areas of manaSement. Dati obt.rined fronrprocosscs must be analysed quickly so thai continual reductior in the\ nficty of wavs ofdoing ihnrgs will lcnd to nev.'r cnding improvenrent.

ln mnny non-mnnufirct l rr ing ope.. t ions therc i r an ' (rcrgy barr icr 'h)Llc srrrnrount.] in convincing people ihnt the SPC npp,orch.rnd tcchniqucs h.rve a p.rri to pl.),. Everyore must bc c.lucntcd so that theyurrdcFhnd and look fd poi(nt iai SfC ippl ic.r t ions. l ia ining in thcb.r\ic ippro.rch of:

no p().css s, i thort drt . r col loci ionjno dni.r col le. i ion witho!t annlysis,n() nnnlvsis without n.t ion;

wi l l ( 'nsurf thdt cv( fy possibl . 'opportunitv is Sivon k) usc' th( 'se PowerfLrl nrcthods k) grc'nkst cffect.

Ir Chapter highl ights' hocess impr(\'('nrents ofkrn follow pfoblcm identification nnd tht

cr.'trtion of ionms k) solvc thcnr. Thc te.rms necd good lcadcrshiP, therighi tools, good daia and k) inkc'nction on process inputs, (ontrolsand fcsoorces.

, ,^ slrstematic approach is requircd to makc Sood use of the fflcts andtechniqu.'s, in r/i areas of all types of orgarliza tion, including thosc inthe scrvicc.rnd public seciors.

., Parck) annlysis recognizs that a sm.rllnumber ofthe caLrscs ofProb'lclns, tyPically 20 per cent, may rcsult in a large part of thc totateffcct, itpically 80 per cent. This principlc can be formaliTcd inio aproccdurc fol listing the elements, mcasunng and ranking thc clcm-ents, crcainlg ih.' cumolative c:tistriblrtion, drawing and interPretinBthe Pareto cur!c, and presenting the analysis and Lonclusions

. Pareto analysis leads to a distinction betwccn problems ('hich arcamong thc !ital fe!\'and the trivial manv a Procedue which enablcsffort to bc dirc.ted towards th areas of hi8hest Potential rcturn

Process l ) r0b e n s0l f n.0 Jnd npr0venr0nt,l

303 x

lh. rnnlYsls is \ i rnple, LrLrt t lx .ppl ic.r t r ( , r rcqUir . ,s n r l is( t t l ine$ir i .h i l l (^ !s f i for t hr br d i f t \ . t r i t ( i th( ' \ i tJ l f , \ \ ' . I t is s( !n.r inrcs. . r l l ( \ l r \B(- . rn.r l \s i ' ( ! Lh. E0,/ l l ) fLr l .l i ( , .d.h ( f i r f t thcf . i f . Usl1.r l l \ r Iunrbcr ( , f . iLrs( ,5. ( , rLrs. . rn( l ( , i te.r, I r r rs is f fo\ rL l fs I s inrph n{) l t ( ) 1,r f rhc kr( t r i i r \ lqf rJfc\P.r t { hrs. f r i r t rn! : t l ic S.rrrr l on i ) l fossihlc. , rL jsc\ l ronr lh( . I f \ , j l | , r t i ( j fl r f . r r rs l (Jfr I l r { s usfr l t ( , l ) |1{ lLr( f . .Lr \ . , r j r l ( ,11. . r ( l i . rS,rr j jc . t !h. , j( ( r r \ t r .Lr . l i f r l l ( l ls l r l ) ( ! r .s l r . , l \ r l r l i , rBr. | f \ . t l r ' .v , r lLr i r l r ( r r (Jr l \ j r ( . .l i r l . i rs.soi . rspe, i l i ( \ l ( ln. . ls l r ( ) ! l ( l b, c\r lur l r t l t r ( inr LI is(Lrrs i ( i r l5t( , ls i r r ( ( r rs ln,( l i I r t . r ( , l r \ i . r , rJ( , t1. . t ( l i , i ! , . i j r r r . t | ( l ( . i , t . l l i \ in1ll l r . .1 i ( \ i . ( 51, ' l , l rs l r l l i t lh qr, , r s. rdrs l iLr . t inr t . r l r . | I ( . ! ! ( , r1. j f ( ( ' r ( li r i f , r l l sul tq st(r l ( . I rs( ,s. rnfL, lJ, j l i I r t th , (1. , ,s t ) r rL,r r ( j , r nr() , . c i f rk.lur(11 ,r f , r lvs is fJ, l r r t : i rJ f ln, ,s l , , r . r . t i ( j fr \ \ , r i , ) l i ,n j ( , , r l lk [ !h j r i ( tLr . rs lh ( . , ! ! . f j ,J f j t . . t L l i i t j . , , r j t r Lt ]. r l { l i l i ( i r r ( ,1 L, j r ( ls ( ( l i l ) \ ( ) l l . r ( , t r ( ( | . ( t : i ( tL.() i th.Ltr , , ! , . I I j :( t r . r r l 1(r l , s iL l i . r I i r i r l f t \ , .1 i . | t 1. I1t ,1. , I r ( l l l i . ( , [ : ( .s \ l i (^ \ / i / i ] !. r r l I f t f , { r , r i ( , ,1 l r l r , .s( , i l l . f ( i rgfn, , ,s J ( ,c nl( . t , \ i \ U\r l 1, , : l r ( t r \ l l i ( , r , I , I I l , , i . . I i i | ,l \ ,1$(1 r lw, , r . r l ( ) rs l ln i r i ( l r t \ , r r l ( , r i l ( . , , , r t r i l l i , rSt . r r ( l t r ( . t l r t \ ! r ( l( ,n l ( ( r , .1|1) l l . ( l ) ( h, i . ( . r , t I l r f r . I l ( ! .q, jnLl , r , r o l , r i , ]L( , LLr l , r r . ( ( , r r t I j l, 'n. \ r l i j \ l1, l , r |

'

| 1( i r l \1sl , r l i l i , . rL i r f r : , . r s,rnr l )k \ ,1( \ l i ( ! r I r ( . th( \ l r js( t l s ln j r l r , t ,L, t . r l ( ! r !, 'n (( ,n ' t , , i ! \ l ( i i r l i l l r . | r . r i t Lh,r f . r ( t ( f is t i , \ l t i \o] \ ( ,s rr i l l . ( l i r l { o l( l i ! j r l i fL( j . r l , j i l l (J jn{ , ) | jh l r i ! { f ( r rJ,s l r n j . , ! l t | :n\ l i r ( ( r I i

'

| | j ( I j r I rr i lh, i l l i . , t ( \ l r r iL l | ( s 1, , t , ,c{ ,n1{ l i i l .n l r r ' \ l t t$1! ,n c| .h L,oUt js.lh. f , i r i ( f l ( ,s,rr r ( l r f r r i ( tufs(J l f r )h lur i \ot \LI1t i | (L i r i t , , . \ ( , I r ( ,n ii r r r \ L) . . r f l ) lk \ l 1, , , rn\ l rL r i . I r . r . l i \ i l \ r . ! , | { | ! l , rq,r t r ( { . r , \ l | l . r r .Lr , [ . r r l ( , t l ] ( .Lr i ,n t l r 's . , f ( . f l r r fs L , i ( i r i r i r , I l r l r ( t rL, i r rg i rn, , r : , , r ,1.l , \ r r (1, l r , rL i r inq , i , l l j . t r , js j ( , j l f f r , . , r l j ( ) t l , r r ts! ( l ,1. , Lot t ( \ i i tnr ,

r . r lv : r : . r r r ( i idr f , , , \L , r ( n l , r ( l ron r j , r \ l \ . r ( \ t ! j f ( \ l

;{r Relerences and further reading( r i \ \L( . \ . N, l l 111){r l ) l / r , / ) r . / t /n1,1,1r, , r15/ i r r r . / r r l ( . )J1trr l I i , r / r r l . , , \S(.) l l i \ i ,

N] ts, , , , t , f . ! ! . L.S\

rs l ' r f . r ( , , ( l l r r6rr) t ; ln l r t1 l \ t t l j t )1 | \ | t r ' )1, r \ r t r r r L! t \ l r r lL! t ! , \ :s( \ . r t r r l

i tnL\ , ! , ( ( i , N] ! l r l . f r r f r , \ l l , r i t r l ( | ln i r l , l \ . (L()1rt t / l , r r r r r r r , r ! /o/r t r r r r r , . I l l | r r ! r r r r r r . . lh l i l f , l l l rLr i r , I i ! r I i f , L (

1). i ( l r f , l , lS ( l t r l )0r l i r l , l Qrrr / r / / l l , r r r r i l ! , r l r / i i r i r r l { ,F, . . , tnf t ( t r j ,ln l r ( ,N\ t r th I l { !n. r r j i r r , ( ) \ l l i !1, L (

l r \ /J.k, l . (L.rr) l j l lJ t : , t tL\ i ; t r , l t / r , \ r \ I r , t r - / l l r r i r r ldrr l . . , \s( . lc ( - tL.r l i r , ll r r \s, \ l i srr l . . , M. l rSA

S\! i \J. [ , ] I1 L)8!) f l r . / ! r fDr,rrr / / l l | t (_, . , r r t r / r , /1, '1/ , r r l r f t ! , r / , t , l , r ,I ) (d! .h! rh I ' r f \ ( , Cinrt , r . i1 lg. , \ ,1/ \ , L l5, \

sI 301 Slatrstrcar Procirss l ]ontro

ttx Discussion questionsI Y()r . r rc thc I \ ( Lrct ion Nhf.S(f of n s rn | ( , fg incer i r rH ((np.r f \

in(1 h.r \ | j l r \ l r . . ( , i !1 'd t l r . to l l ( \ . nr nx 'nr() :

l ( r , l l f ( ih i r \ ! ( , rkcJ l r , r f ( l t { i S.r r l r ls { ) r (11. l , ) , us t ( ' nr . rn|1n.tun. l t ,00t)\ r r l i t , l \ l ( ) f l ' ( - ) l l 1.1( l l l ( , ) , i t r t ( ls n( th.rr r l r f r , r r ' , rh j r t roR, lUfrrl , r , r1. , , , I I ' r '

- .

| , ' ,

r . \ , l , , , r i t , t . , t , , . . , . . , . . . , r .l , l \ lh. t 1h. \ l , . l I s l l r ' \ , r r ' , , ( , r t r l f ( l i tJ f I nrusl l Is st lh,r l \ ( , r i [ ] ! ., r ( t i i i ( . r l , ) . , ,1 r l r rs l iu l l \ h i l f l r , rUnr l \ ' r dr ' t ) r i ( r i ty , r f ( l lh.{ v()r lr j j . rk. su r . lh,r l l l r r5 r l tn\ nol f . ( l r . r \c \ ! , I l j r ( , \ ! l ' ( - ) l i I t ( l , r [ . . r rx\ i, usl{)nr ' r t , r i r ( l l lx \ ' ( , ) | L l f r l . r l (n () l r ! ' r l or r $,rvI f , i { l ( r l , r i l \ Ih. ,vclk,rnl th l l !orL r , r \ ( b i1rr s.rk l jnr t , r n r l \ , f ( ) lv i 'uf ( i f . r .1() , \ ( ! r , r l r , r nLi ,g , ( \ s( LI l l i . Lr{ . (J l th( . r r r ( , ( )L) , I r l i. . | . ' , | . . . ' . t . , , ' r . , \ i t

' r l , , , t \ , . . I , . , . , r , , , , ,11l l , , r f . i f r lh,r l I0Lr s l0rr l , l l r r r c s l t | t r | l , nr(rx\ ( ) r r , . I rptorLn! njr) r .r I r s l r \ l I f ( ! l r ( I j , rs l \ \ l , ) fs, r i j t l r . r l l r , I ) ( ! r l , r i , j i l l t .ours,s, j , rLI l r i l t ll f ! l ' r r ) l ( i r t \ l ( s l inq ( \ l r ipnr ' f l

1f) ( ) rLt l r t h( , \ ! v()u i I l ( . ( l 1()

l ) is . rss I h, . , ih.r I pI f . r l t f . r t l i

, r i \ ( s l r l t , ' l ( . l l ,cL, I rs.sr iJ lh( ' lJLr l lv '

N{t,M()t tr \Nt)L \4I lulLr l i ( in Nl.rnrgf l

t t r l t t \ , t l , r t . ) t )1: /11, /

I \ 'orL h.r \ f i I lx r i t .L l , ! r j f \ f . ( l , r l l \ , r sr j r . r t t ( , r r j rn\J i I t b l \ inc: \r h i ( h \ L)(nlr th lL l , rh i ( , .1r(1 ( .1( i \ \ r lUl l (Jtr l ( r h( ! ,k \ i \ r wish l , , t rcfcf !nr . r l l , " in\ (n! ( \ l j , j lh is.r l i \ L l \ [ l ] .R t l l ( ) r r l \ . r f t , . r ( ' t inrrx,r l jn l ( ,.1, . (enr is lh hirh lerr , ls rn sr . . . rp.r I r l r ( \ ! { , f t (osr i r rB r{)gf lhrr nsun' .qui \ . r l { r r l l ( , . r l roul l l i l . f , o l (n Ih r . , i r r f r I \ "s l ( ) t r l snk, \ .i ) rs(uss \ { ,uf orcth(tr j (Jt f fogr.1ssi !e l . f Pi( l ,ng up, . r . . r t rs i r rg rrr l\o l \ i r rgthis l f (n) lerrr ( ) \u r l i f lot p.r i ( \ l (n l2nronr l \s l l lLrs l r , r r f . IV, i i lhf t t r l iqu.s \ , , ! ! l is .ussl) i \ . r 'ss r (1. t . r i l thr nppl i . . r i ion\ o i l , . r f . t {J.rn. l \s is rrk l . rus(,nId. lJr . t . r f . r l \ .s is.rs.r lds in s l , l ! i .g ot) f r . r i ions nr,rnng. 'nr t !1 l t fob[ ,nrs.( ; v. . r t l f . rst t$1) i l lLrstr . r t i (n ls.lou nre r{ sp( l rs ibk, for i t r isrLr i t pfuda.t j ( ' r p l in i , nrrd r f r conc,mfdnbout th. ( r+rut i f t ) rn ihc l inrs t rh i (h mrk. 'ch(xolrr ! lvholenrc.r lLr is.r i ts (htpuL is.onsist(r( l \ s igni i r ( rnr ly below t . r rgrr . \ i ru sospect th.rt dlis is bec.ruse thc lines .lrc frcqucnrly sbppeLl, so i,oLr injri.ti'nn ln rleptlr investig.riion or or n t\'tii.dl 2 !\,ck pori(\]. Thc tablcbel(x\ , sho$,s thr c.Lrs. 's o l thc stopprgcs, fumb.,r ot ( r ( .stons on

6aPi0cess prob em so vino and rm!r0rcme r l

rh ich c ' . r . l r occLrrrocl , . jnd th i ' n\cr lEc.nroLr l r r ( ) f ouq)Lrr t ( ,st (nr

305

Cause No- ot occurrences losl producl ion(00s biscuits)

3100

l3

25

I

Averaqe cosl 0l warranlywolk (per claim)

2189

189r5.608291t

5r9r0.2

L,! , lhs ( l , r l . r JI( l th, . i lJ t , r ( ' | f , r t , ( \ ] I r iL l | ( . \ r ( , in(1tr . , r1. $trJr . t , j( ( f r ( ! ) l r , r i . r . r j i . ( l r , r l , r . l i ( f rI J()$ L { i r l ( l . . / r / / r l r r / r ! r , r j r l t | l , , rnr l \ ! is i I th i , t , . I t i ( ut , r f L.r : f l/ \ r ( ) r i r f , rn! nr , rnI l , r . tu,1s i j r , rnr . ( ) t ( l ( j r f , .s l i ! L, l ( \ . t r i ( . , r . j t t | . r r r ! . ,l ' . r l i (u l , r f . ( ! r . r . \ l ) . r t ( \ t l r5sf( l , rb(rr t l l i . s , , r f f r . l l I , r inrs( ! r1) f , P,r ' l , (u l . ' r l l r lLr( t . I l r ' \ | \ r ( rnr f f n. f \ r f ( l ( ' | . I tnr . r j t l ) r0! i ( tL,si l r ( l t , l l , i \Mr i , l , r l . r r l . l f t i r+t th, . r . l , r i r i rs t , , ih. L,r j i l , / . ( )nr f , ) , r , I i I , r . l ( ) ilh, lnr l , , ( t t r l r i { h . , r l ,s . r l t l r ( ( l , r i , r ) :

cel l rpha 0 ! r r i lp breakauN

lJni l /component parl

0nrnuir : in l l

Eleclnc motor

Door lock mel jhan smSlabi zer

Ekclr ic conlrolu r 1S!, ' tchrng mechanism

t03l

102

2l

87513

Number ol c laims

I t0128,12

14??46798621

18442692

7562652

1124

xI 306 Stal s l ca Process Conlro

Discuss what critcri. nre ofimportance in identifynlg those unit/component p.1rts to cxamine initi.rlly. Cany out a full annlvsis of ihe data toidentity such unit/component prrts.

5 The princip.r I c.r u ses ofacciclcnts, their percentntc ofocclrrrence, andthr estimatcd resultht loss of production pcr rnnum in the LIK isgivcn in thc table belolv:

Accidenl cause Percenlage ot all Estimated loss ol prcductionaccidenls (fmil l ion/annum)

[,4achineryTransporlFal ls Irom heighls .6 'Tr pp ngSlrik nq against obiectsFalling obiectsHand ino ooodsHand toolsBurns ( nc udinq chernrcal)Unspeci led

t6I

t6391

2l/52

r9030

100t0l

2031065l53

f r ) Using thc:rppR,pr i i t ( ,dnt . r df . rw i 1) . r |1 lo cur\ ,c l r rd sugg( sr howthis nrny bc us.{ l m'st of f t . t i ( ly to l ick l ( ' ihc pfoLr lems oI .c( . i( tcnt prevt 'nt i (D. t low co| | ld str . r t i l i ( . r i ion h( lp i r r the in i lys is?

(tr) ( l i !e threcoth. f us(sof th is tyt)( of nrnl) ,s is in rurrn.rnUl.r . tLrring nnr l exPlnin br i f f lv , in cx(h c.rse, ho\^, uso ( ' f lhc t (chniqLrer ic ls impft , \ 'enr(nt

I hf mnnufrcturcf r ) f donr i 's t i . e lc{1 ( .n1.pPlhnces h.rs bccn c\ .nr i r ri fg.nus.,s ol r ! , r f f inty. l . ims. Icn ha,,c betn idrnt i f ied.nd lhc.nnunLcostof w.rr f lntv lvork resul t ing l fonr thcst is . rs n) l l )ss:

Cause Annual cost ol waranly wo* (f)

BcDE

GflI

10902130

30690620

5930970

49980106049803020

&Process trnb em so v fq and nprovemenl 307 t

C.f .y out . Pirck) rnl l \ s is (r1 thr nb(\ c ' dnhr, . r d dcscf ibc h(^! thcnr i i f . .us.s .oulLl Lrc i11\ cst ignted./ \ nrortg. j t . . ( inrpdrv t inr ls th.r t sonlc l (s p(.r c( .nt o l . rppl i . r t i ( ,nnrnrs n.( i rccl t (nn (Lrsknncrs cr not bc proccssi 'd i lnnrccl inh, l ! ,r^r ing 1o th. nbsrn.c () t s(D1c () f thf infof lnnt iof . A s.rnpl f r ) i 50( lin. , )nrpl( ,h, .ppl l . . ( ion tornrs re\1t ls t lx to l l ( t r ! i r rg d.r t . r :

In lormalron missinq Frequency

Dilyl rir{r lelcphono n rnrb.r

flor!f oMrfil0rjcul)LcrHo r | 1r l l ih.) i r r nImhor

Sof l f lo Lolo

Prefc ' r0r l l rc l | |01 ol ! i tyrrnl0lher i

9222

l

fit5l

t ( l

u521

l)(1rtrni . , lh( D. ' ] , { , , "A$ ol nr is ' i rg i I r I , ) | | r '

n t I ( | , , . i , rL i sLrgi tesl. rpfhpr i . r l ( l ( .h. i , t ! r ,s lo rLs(, in l ( ! r r rcJ.s i l - r to redr( t l ln l r r ir l . I .c ( ) l t rL\s!rrg lnr() f nr , ' lk , r tALLrrrparr l $hic l rL l ' r ' I lessi lhr l $1! ' l rL( . rLnt i INl t r i ( \ l is f \ lu i. r r ing dLl i i r r l l i rs i f Lccl)Lo:t Lr t Ni lh lh( ,pr . fJrr l i ( r r , i rk l issr( o lsr l .s l r \ ( , i . ts ( lur iDl j thr l is l t ! ,1k (n l l ) , . r ( . { )urr l i r rg fer i { t l . l ) , r l , rL () l l . ( t ( l ( \ er lwo i ( , ( ) !n i rnt p( r i ( \ ls nr . rs l ( ) r ( \ ! sr \ f .ornl in$ 11 r io. l INonrl)cf ot srk s in\ oi .cs issu.r lA(.ourt i rrg l ' . r i ( 'd 5NLrnrb.r oi s.r l rs i r \ \ oic. 's issue(l

N.. l l2 l . l| 0 27) 2l r .r95

\ \ f rk l2 l . l212 207 3| ] 270

I i \ . t rn inennlcorfc la l lo ' rbetr ! r 'c . ihrs.rk\ ! i thnr lh. 'p. ' r ior1nn. l i i recl .nunds pl . rcd on thf i f \ , ) icc Ll .p i r tnr i t t . How would \ 'ou lu i t i i tenct ion to in lpro\e lh is s i tLr . i i (nr l

:gx 308 Stat ,strcal Procesr Contro

Worked examplesReaclor lVoo-pv ol , -sppL tF\Lt l \

]};x

, \ fn) tc( I lcnnr kbkirg nt inr f ( \ t I r , r ( , . r { to l Nl( ! ! r . \ .o|hr) t ( . r r f ( , .suR,ol

\ rs.(*r t \ lnr . ' r l { , )*u( l \ ( \ . f t . l l r \ t r (1tnr, t r t ,s,) t I ,sLr l tst , r j | ! s \J ll \ i rnr \ ( ) ! ts( ]ct l r .$.r l t , , r i r r . t t , l , i i l \ , ) i lht , . . rLrq, ,s\ . l , l ish\ l ( jJ l , t ( ,

.6) .Table 11 6 Fei lctor [ lo0 rey 01l s lsc re: jLr is over ] 4 prortuart l )n days

Sample

l

t:l

L

Jl l12

It il i

23

2526?i2829303l32

Sample

33

i{t39

1l1?

.15

1il8

50! l: t?535155

53

60

E26364

Cause

H(l t ro[r I

l l C L | r r l r ( r

lC L corLroll lCL r . i ] l l ro

0!ur cor l ]ct on F 109

HCL cot l rof l C L controH C L. conlrol

Cause

I ( l I co|rro

l i ( l m r l /o

l l ( l 1]0rtr i lf lC L mnrroli lC L oonr ol lC L co/r l rc

&Pr0cess pr0bl0 n s0 ! rq and rpr0yenenl 309 t

Table 11.6 (Conl nued)

Sample Cause Sample Cause

65666/6869707lt2

73i1T5T6t1787!80

l lC I cor roh C L conlroH C L cofir.

H 0 L conirol

B No c!n1roB No col l l ro lH( lL co r l rof l C L .onl 'o

trs i f l t , r f , rnLinL,rr t lk ! l l ' , rk l ( ) . r rn l ,v5rs I l r f l f , rnr t r1 ,c.r l , l ( , t ( jLI( . i , . fr ' r i r t lh, dr . r t ( , r . . . rs ( in $ hi .h l ( , . ( r r ( | l r , r1( , I l l . i f r ' l t , ) r t , r .' i l ( | \ in lh. . r i r ! : i \ $r . r ' , r5 l , ) l l ( \ !s:

( , )Lk\Li . r l , r (^( f l - l | , ( \ lLr ! l i ( ! r ( l . r \s,r . ( l l , rLrulr t ( ( l : rb l ( t I r , ) .( | | | . r l ( l l r ' l ( ) l , r ls() l cr(hrfLrs, , i r r l ( l , l . rnr In t l r ' ( i r l ( r ( ) r 1, .i t !e, ! \ ( . { . \ \ 'hk h . , r is . ( \ ( Ur: r i r r ) r l r , l l . i r )l ) , . ,s Lrf , r l , r l )1, , in, i r r l ( . , ( , i 1r . ( t r ( r rv, ,1,rr . r , , . r re( l rhk t I ; l( , r l ( u l r l f Lh l , . | r , .n l , j { . ( ) l t lx l , ) t , r l ( , l j : | ( r t ] j , ,1 e.r i r , I rs, . js

i.l

r . ! , . I \ ' r . . r l r l I ( l r ( 1, i , .n! l ( ) r r l i ( ls i l I 11) l r ' , , , n l

Rankinq in managitq product range

' t l

( LI fLr l , r1, ih, . r , .ntr . r r ( \ ' l tn, n l r l l sl ' l ( ' l r l ' , r f ( l ( i l t r i I l i s l r ( ) { i r+t l l r ( f .n.(nrnge JLr. lo. . r .h . . r l 5. .1r(1t l r ' . r r rnLr j , r l ! r . f$.r , i l rg. i f , \ lLr ' . r \ t ) l lherrUs{slrr)nr l i l r l . l l 7( l i l tLrr ' l l I l )

s{ , r ( i igur.5 $1r. pf( t r1u.(11 b! . r s,rr . r l l r l t r nr i ( . r l .onrf , r r \ c(nr. f l r nrlhc conrt) . rn\ 's f r tur lucts, lhr , i f lo l , r \o lurr . (s) , . r r rJ( l i rcclcosts. lh.sr, r f r g l \en in I .1bh l1. i l . Ihc I ro( lLr . ts

' \af . f i r rk.(1 i . ofd.r o i inr(nn(

nf( l l ronhi l rut i ( !1 hn lhf pr+)osf o i l ' . r ren) r . . lys is, nn. l r | l ,R\Lr l rs.r ! g ivrrr i r r l rbL( 11.9 I (J considor c i thcr in.(Dre or contr ibut ion inthe r t rseu.. 'ot ihc (nhcr cor ld le.rr l n) i . ,ofr(ct c(rrc lusi( ! rs; roff r inrpl . ' , pror luct 013 s.hich is r .nkel l t ) th in in.onrc nctrnl l , " nr ik.s

Table11,7Reeclor l ;ar . , t , r f j -s. .e:re5Lt:aiar: , ! rNotcirr lat3s! : :a l !anarsj t f ra ls:Ts

-

neasons lor Mooney ofl-spec Tal ly Frequency Prcenlaqe ol lotal C{mulativepercenlaqe

fl C L contrc

Oal PN sonsD rly st c( reacliiI No ccrtro

0!ercnnirdan F t0g

Lab resu ls

l.l

l3

:

l

3l'25aJi52525i25

r25r25

{070825875

93 7596.2597598 /5

100

Bl i r : i

t i.Eia! / -

eai i

st311xProc0ss prob em so ! l ! and f iprovenrent

r0 !0 i to, l l t r ,1r r io 70 30 . I ] 100

Fiqtrrc11 14 r ' . I i t ,0, . r | f [1]r !

Table 11 I Sontc prorhI ls.rxJihc I to l r l !1] l

aq r ')

Codenumber Descripl ion Tolal direcl Tolalc0sls ($) c0nlr ibul ion {$)

Tolalvolume ($)

0{t l002003001005006407

Crpl re8H0 DUB0DB St l fh

DOB

tu40Iti2.10t( i00( lJ2500u800

t06E2l2600

tu5t5/ /h2295A4000

0 79

(Cof i i r edl

r066b0rb224

195504600

456421456

, t Table 11.8 (Continued)

C0de number Descrption Tolal Totat direcl Totalvolume ($) c0sls (g) c0nt.ibution (g)

0080090100i1012013014015016417018019020

640028890011340011700120002080037500113006394538800236501346714400

9041232649541062002580

2080095002486

44406254634301160307200

5496r656361799055009420

0280008814

19539r33371935074377204

D moxONT

HETB

Derros PyrelheneDifosab[,4a eic HydrazoneThirene'BHD0nosn

Chioropicrene

Iable 11.9 lncome ianh/conlnbutron rank Iable

Code number Descripl ion Incomerunk

Conlrihotionrank

0010020030040050060070080090100114120lg0140160166170rg0190a

caplineBHD.DDEDD8-S! phurN cot ne-Phos

DDBD moxDNTParalhofHEIEMepoloNDsrros'PyrthentDrno$eblveh

Hydra&ncTh rrn'BHDDiiq n2,4.PFhosphnrhlorBprrnB

2A108

112

I1

6

2010t l5

173

19181

7

tp

t:l&s0,r rq fnd mproverner l l |3

()n. \ \ , r \ f i r h,r f r l l ing t l r is t \p. of fJrrkrd r t . r , r is l ( j f t ( ) t , r r i r . , , I jc, ( r rh ' r l i ! l l i r r r , rn l .h id ln lh is t t r f i l )5. tcs,r . . r r , l t r ( , in\r)nr. f . l r ts, , | r ( lt l r ' ( i r ( l r , r l , \ .11 rht , , . . r r r fbr t i t r r r f I t5 r \ l , r r r tL, , l 0t1) h,r i . I rI r ( r ' r ) i . . ' f l \ ( i l l , i f r l , r L( i f t rL,ul iorr r r r r [ ( ) r ; . r r . . l ) r ( r tLr( l0t0 {' . fn. : r ! ' l t \ l l , \ rh. t t , j r r 1-1,1.) j r r t , i l t r . I t i . t r r ntr i ( t ) . r l l r l \ , f | rLslr i ! ( t r t ! . f l , l (nt(r l i I i l i rs t r . \

xmffiff"KffifiHV

g Pror6FE (rapolr i i i t r / in a i lankI l l ! r i I1\p\cr,dFdhi l i ty i l ] ! i t fbq r ! l f Ulntt ni i ] ] \ l r ! l t r l t l l ll , rL ubi q ro r , , l Lr l . r l r l ! r , r r l t r l t t ra I t ! I . r1 l . i i , , dtrrb

Fqr!11 15 , , I , I r r l r , I , l

( 1. . ' , l , j . 1 l r r \ f l ) rL)( lL,( l : . rh,^ f t t rc. l5 l i ] l , , l r , r \ r i j ( i , I r r r . r i r t i r rE! , ig l r i . ll l ! . rn l l l r ' l r | l r l t t r i l r i t l i r r t ! | f r r l l ts , I l ! i nr , l } t ) !L, I rL l t . t r l fs l r , r }s i t f r l r r l .r l { r r1, l . \ |s r , t I r ' t ! , r6Lb tr l l i r i r ! r l r r r , ( l | .15 l rp l t l r f l l t r r l r Iu,Lrr r , r ! ] | \ lgrr) ' l | l I r l r lhrr l l {xt nr i r l bpl l i Ig I l l r t l ,

' r l lh!ni $|rr l r i hr , l , r , r t r , l t , r , t l I r i "J r , ' t l , ' , , ! l , , , , , ,1 l , { , r" t . I ( , l i t , , , , . l t r , , r r , , . , t , , , ! , r , r . t . . t , " , r l l . t r . i l| ' | . , | | I

' |

'

, b ' , , . I | | . I i , , I l , t , ,Hr, , t r t . , r , . b. . , r | . t , l . . , rH," ,1, , . , r , r t . r r n

El:,

xI 316 Stat st lcat Process Conrro

led .n effort b nnprore transncfior eftj.iencv Ttris ircgnn la,fth a ftov\-c'h.rrtifgolthc proccss.rs shown in trigurc .16. tn additi(,n,.r brrinsrornrscss'on hloJving thr .ashi(,rs $,as used to J.iener.rk,ihe cause and cffectLliigfan of ligurc ll.1Z A quatit_r impro\(,nrent rcinr l{,.is firrmec:], flrfther daLr .ollectctj, and thc'vital'arc.1s ofjn.ompkrrety undcrsbod pr.(|ccdurcs an(l cashr( r irninin8 r,.,ft, tacktcd. Ttris rosulied o\ cf. peituJ ()f6 months, ir .r rcduct,on in nverag. rrnnsadion tinrc and ilnP.ovcnr.,ntIn process cnt)abilit)l