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Solitions 19-16 and others

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Solitions 19-16 and others Powered By Docstoc
					                                                      6/30/2010                                12/31/2010                                 6/30/2011
                                                                    % of Total                              % of Total
                                                        % of                                      % of
                                     Actual                          Quality Actual                          Quality Actual
                                                      Revenues                                  Revenues
                                                                      Costs                                   Costs
                                                        (2) =         (3) =                       (5) =       (6) =
                                         (1)         (1) ÷ $8,240 (1) ÷ $2,040     (1)         (4) ÷ $9,080 (4) ÷ $2,159      (7)
Prevention costs
 Machine maintenance                          $440                                    $440                                         $390
 Supplier training                              20                                       100                                         50
 Design reviews                                 50                                       214                                        210
  Total prevention costs                       510        6.19%        25.00%            754        8.30%        34.92%             650
Appraisal costs
 Incoming inspection                           108                                       123                                         90
 Final testing                                 332                                       332                                        293
  Total appraisal costs                        440        5.34%        21.57%            455        5.01%        21.07%             383
Internal failure costs
 Rework                                        231                                       202                                        165
 Scrap                                         124                                       116                                         71
  Total internal failure costs                 355        4.31%        17.40%            318        3.50%        14.73%             236
External failure costs
 Warranty repairs                              165                                        85                                         72
 Customer returns                              570                                       547                                        264
  Total external failure costs                 735        8.92%        36.03%            632        6.96%        29.27%             336
Total quality costs                      $2,040          24.76%       100.00%      $2,159          23.78%      100.00%         $1,605
Total production and revenues            $8,240                                    $9,080                                      $9,300



  2500                     Quality Costs (Total $)
                                                                                                                       10.00%
  2000                                                                       Total prevention costs
                                                                                                                           9.00%
                                                                                                                           8.00%
                                                                             Total appraisal costs
  1500                                                                                                                     7.00%
                                                                                                                           6.00%
                                                                             Total internal failure costs
                                                                                                                           5.00%
  1000
                                                                             Total external failure                        4.00%
                                                                           costs                                           3.00%
    500                                                                                                                    2.00%
                                                                           Total quality costs
                                                                                                                           1.00%
       0                                                                                                                   0.00%
                   1             2              3               4                                                                         1
 6/30/2011                                    12/31/2011
               % of Total                                     % of Total
   % of
                Quality Actual               % of Revenues     Quality
 Revenues
                 Costs                                          Costs
    (8) =        (9) =                           (11) =         (12) =
(7) ÷ $9,300 (7) ÷ $1,605       (10)         (10) ÷ $9,020 (10) ÷ $1,271


                                  $330
                                        40
                                       200
      6.99%        40.50%              570           6.32%         44.85%


                                        63
                                       203
      4.12%        23.86%              266           2.95%         20.93%


                                       112
                                        67
      2.54%        14.70%              179           1.98%         14.08%


                                        68
                                       188
      3.61%        20.93%              256           2.84%         20.14%
     17.26%        100.00%      $1,271              14.09%        100.00%
                                $9,020




            Quality costs as % of Revenues



                                                            Total prevention
                                                          costs
                                                            Total appraisal
                                                          costs
                                                            Total internal
                                                          failure costs
                                                            Total external
                                                          failure costs



1              2            3            4
Part 1)   Data:
                    10   =number of advisors
                    10   =hours/day worked by advisors
                  4200   =students advised
                    12   =average minutes/student advised
                   300   =students/day

          wait time =         9 minutes

Part 2)   Changing students/day to 420 above gives 31.5 minutes

Part 3)   Changing time/student to 10and students/day to 420 gives 11.67 minutes
                      Data:
                                12   =number of advisors
                                10   =hours/day worked by advisors
                              4200   =students advised
                                12   =average minutes/student advised
                               420   =students/day

Option A:             wait time =           14 minutes

Option B: Changing to 350 students/day and the original number of 10 advisorsalso 14 minutes average wait!
nutes average wait!
Data from problem

Prod run    DBBs      UCL       LCL       HWSs      UCL       LCL
        1       18.23     18.53     17.41    14.11      14.32     13.68
        2       18.14     18.53     17.41    14.13      14.32     13.68
        3       18.22     18.53     17.41    13.98      14.32     13.68
        4        18.3     18.53     17.41    13.89      14.32     13.68
        5        18.1     18.53     17.41    13.91      14.32     13.68
        6       18.05     18.53     17.41    14.01      14.32     13.68
        7       17.84     18.53     17.41    13.94      14.32     13.68
        8       17.66     18.53     17.41    13.99      14.32     13.68
        9        17.6     18.53     17.41    14.03      14.32     13.68
       10       17.52     18.53     17.41    13.97      14.32     13.68
SD               0.28                          0.16
Mean            17.97                        14.00

                                 18.8
                                 18.6
                                 18.4
                                 18.2
                                   18
                                 17.8
                                 17.6
                                 17.4
                                 17.2
                                   17
                                 16.8
                                         1      2     3     4     5     6



Data generated with the actual mean and SD that is expected, with only random error
So this represents a process NOT OUT OF CONTROL!
Prod run DBBs           UCL       LCL       HWSs        UCL        LCL
          1     17.84       18.53     17.41      14.15       14.32       13.68
          2     17.58       18.53     17.41      13.80       14.32       13.68
          3     18.01       18.53     17.41      13.95       14.32       13.68
          4     18.03       18.53     17.41      14.02       14.32       13.68
          5     17.31       18.53     17.41      14.35       14.32       13.68
          6     17.73       18.53     17.41      13.95       14.32       13.68
          7     18.17       18.53     17.41      13.96       14.32       13.68
          8     18.06       18.53     17.41      14.16       14.32       13.68
          9     17.86       18.53     17.41      14.03       14.32       13.68
         10     17.66       18.53     17.41      14.01       14.32       13.68
SD           0.28                                 0.16
Mean        17.97                                   14

       Press F9 to recalculate the random values above, see result in graph:


                    19.00
                    18.80
                    18.60
                    18.40
                    18.20
                    18.00
                    17.80
                    17.60
                    17.40
                    17.20
                    17.00
                            1     2     3     4          5   6   7    8        9

       Truly random series don't always look that way to us! We expect regular up/down patterns
       The point of the exercise here is to see what random patterns can look like.
            SKPs           UCL           LCL
                   15.83         16.44          15.6
                   16.11         16.44          15.6
                   16.24         16.44          15.6
                   15.69         16.44          15.6
                   15.95         16.44          15.6
                    15.5         16.44          15.6
                   15.86         16.44          15.6
                   16.23         16.44          15.6
                   16.15         16.44          15.6
                    16.6         16.44          15.6
                    0.21
                   16.02




                                                  DBBs
                                                  UCL
                                                  LCL




             7       8      9      10



only random error

            SKPs           UCL           LCL
                   16.19         16.44         15.60
                   15.77         16.44         15.60
                   15.81         16.44         15.60
                   15.95         16.44         15.60
                   15.73         16.44         15.60
                   16.16         16.44         15.60
                   15.90         16.44         15.60
                   16.13         16.44         15.60
                   15.87         16.44         15.60
                   16.01         16.44         15.60
                     0.21
                    16.02

ult in graph:




                                DBBs
                                UCL
                                LCL




                9    10

e expect regular up/down patterns, and we naturally try to see patterns.
terns can look like.

				
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