PART A

Department MAINT Admin OPS TRAINING SAFETY Total No. of Injuries 40 5 5 4 3 57 % of total Cumulative Percentage 70.1754386 70.1754386 8.771929825 78.94736842 8.771929825 87.71929825 7.01754386 94.73684211 5.263157895 100 100
50 40 30 20 10

Pareto cha

It shows that 70% of total inturies are occuring in maintenance department. As per pareto principle, working out to avoid injuries in maintenance department will reduce the no. of injuries

0 MAINT Admin No. of Injuries

PART B
Department Training Safety Admin OPS MAINT No. of people 5 5 10 10 200 No. of injuries 4 3 5 5 40 % of injuries 80 60 50 50 20

Departmental In
Cumulative Percentage 50 80
40 30

it shows that the training and safety departments are showing highest percentage of injuries at 80% and 60% respectively. Here, maintenance department turns out to be best with just 20% injuries. Hence as per no. of people and percentage of injuries in each department, working out on training and safety departments are to be done first, followed by Admin and operations at 50% injuries each

20 10 0 Training Safety

Pareto chart for injuries

100 80 60 40 20 0 Admin No. of Injuries OPS TRAINING SAFETY Cumulative percentage of injuries

Departmental Injuries percentage

100 80 60 40 20 0 Safety Admin OPS % of injuries MAINT No. of injuries

Category School tution Visa Fund pledge Mastercard Car loan Other loan balance Total

Amount ( Rs.) % of total 2,030.00 16.9917134 2,007.00 16.7991965 2,000.00 16.7406043 1,983.00 16.5983092 1,971.00 16.4978656 1,956.00 11,947.00 10,000.00 16.372311 100

Cumulative Amount Percentage total 16.9917134 2,030.00 33.79090985 4,037.00 50.53151419 6,037.00 67.12982339 8,020.00 83.62768896 9,991.00 100 11,947.00

2,040.00 2,020.00 2,000.00 1,980.00 1,960.00 1,940.00 1,920.00 1,900.00 School tution

Available Amount

As per pareto chart, 83.6% of due bills will be paid. It shows that available amount of Rs. 10000 can be used to pay all the bills Hence only 16.3 % of total due bills shall remain.

Other Information Catagory Interest Rate % Visa Mastercard Car loan Other loan balance School tution Fund pledge 21 18 9 6 2 1 Applying the applicable interest rate, the new payable bills amount is shown in the table below.
3,000.00 2,500.00 2,000.00 1,500.00 1,000.00

Bills Paymen

Category School tution Visa Fund pledge Mastercard Car loan Other loan balance Total

Amount ( Rs.) % of total 2,456.30 18.7610941 2,368.26 18.09 2,180.00 16.65 2,101.98 16.05 2,010.42 15.36 1,975.56 13,092.52 10,000.00 15.09 100.00

Cumulative Amount Percentage Total 18.76109412 2,456.30 36.84974321 4,824.56 53.50047203 7,004.56 69.55528806 9,106.54 84.91077348 11,116.96

500.00 0.00 School tution

Available Amount

Using pareto chart, the bills payment schedul 100 13,092.52 charges has been applied and hence amount shown. Here, paying four bills completely wil complete and partial payment of car loan can Rs. 895, to avoid interest payments

Bill Payments
120 100 80 60 40 20 0 School tution Visa Fund pledge Mastercard Car loan Other loan balance

Amount ( Rs.)

Cumulative Percentage

0000 can be used to pay all the bills except 'Other loan balance'.

Bills Payment with interest

120 100 80 60 40 20 0 School tution Visa Fund pledge Mastercard Car loan Other loan balance

Amount ( Rs.)

Cumulative Percentage

to chart, the bills payment schedule gets changed. As interest s been applied and hence amount payable with intrest has been re, paying four bills completely will make 69.5% of bills payments nd partial payment of car loan can be done with balance amount of avoid interest payments

Reasons
Size out of specs Fuzzy grain Machine tear out Burn marks Stain Loose knots Splits Raised grains Dents Oil grease marks Total

Frequency
194 105 61 44 31 18 11 4 3 2 473

Relative cost of rework

4.92 0.72 0.09 0.06 1 2.34 0.32 1.76 1.75 0.03

cumulative frequency of reasons

41.01479915 63.21353066 76.10993658 85.41226216 91.96617336 95.77167019 98.09725159 98.94291755 99.57716702 100

250 200 150 100 50 0

Frequency

Here, as per pareto chart, top 3 quality problems(size out of specs, fuzzy grain, machine tear out) constitues 76% of issues top 4 problems(size out of specs, fuzzy grain, machine tear out & burn marks) constitutes 85.4% of problems. Hence these problems of quality should be solved on priority to achieve maximum results of upto 85% reduction in quality issue probl

Reasons
Size out of specs Loose knots Raised grains Dents Stain Fuzzy grain Splits Machine tear out Burn marks Oil grease marks Total

Frequency
194 18 4 3 31 105 11 61 44 2 473

Relative cost of rework

4.92 2.34 1.76 1.75 1 0.72 0.32 0.09 0.06 0.03 12.99

cumulative frequency of reasons

37.87528868 55.8891455 69.43802925 82.90993072 90.60816012 96.1508853 98.61431871 99.30715935 99.76905312 100

Quality prob
6 5 4 3 2 1 0

Relative cost of rework

Here, cost of rework analysis shows that size out of specs accounts for highest i.e. 37.8% of costs of rework. Also, size out of specs, loose knots, raised grains problems and dents constitutes of 82% of rework costing for quality issues. Hence these four problems are to be resolved on priority to minimize expenditure on rework.

Quality issues
120 100 80 60 40 20 0

Frequency

cumulative frequency of reasons

out) constitues 76% of issues and 4% of problems. Hence these 3-4 uction in quality issue problems

Quality problems rework cost

120 100 80 60 40 20 0

Relative cost of rework

cumulative frequency of reasons

Job Number
301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341

Problem/ Customer type

F/R O/R N/C N/R W/C N/R F/R N/C W/R N/R N/R F/C N/R W/C F/C O/C W/C N/R O/C F/R F/R O/R F/R N/C F/R O/R W/C O/C O/C N/R N/R W/R O/R O/C N/R W/R O/C O/R F/R N/R O/C

Row Labels N/R F/R O/C O/R W/C W/R N/C F/C Grand Total

Count of Problem/ Customer type 10 7 7 5 4 3 3 2 41

In case of residential customers, 3 proble problems of noisy equipment, equipment fa 40% of total complaints is th

Residential customer Problems Type of problem count Noisy 10 Equipment failure 7 Odour 5 Runs warm 3 Total 25

cumulative percentage 40 68 88 100

Commercial customer Problems Type of problem count Odour 7 Runs warm 4 Noisy 3 Equipment failure 2 Total 16

cumulative percentage 43.75 68.75 87.5 100

in case of commercial customers, odour problem constitutes 43.75% of all the problems warm running constitutes 68.7% of problems. Hence solving these two problems will res resolution

n case of residential customers, 3 problems constitue 88% of problems. This includes blems of noisy equipment, equipment failure and Odour. Noisy equipment consisting of 40% of total complaints is the priority area to be worked out.

Residential customers problems

15 10 5 0 Noisy Equipment failure Problems count Odour Runs warm cumulative percentage 150 100 50 0

Commecial customers problems

8 6 4 2 0 Odour Runs warm Problems count Noisy Equipment failure 120 100 80 60 40 20 0

cumulative percentage

m constitutes 43.75% of all the problems. Problems of odour and ence solving these two problems will result in 2/3 of problems

Interval Number of Start defects Time

8:00 8:15 8:30 8:45 9:00 9:15 9:30 9:45 10:00 10:30 10:45 11:00 11:15 11:30 11:45 1:00 1:15 1:30 1:45 2:00 2:15 2:30 2:45 3:00 3:30 3:45 4:00 4:15 4:30 4:45 1 0 0 1 0 1 1 2 3 1 0 0 0 1 3 1 0 0 1 1 0 2 2 3 0 1 0 0 1 3

Number of defects
3.5

Number of defects

3 2.5 2 1.5 1 0.5 0

Time

As per runchart, various peaks can be abserved and the trend is showing an increa However, it is observed that no. of defects is maximum at 10:00, 11:45, 3:00 and 4: range of tea breaks at 10:15 & 3:15 and lunch break at 12:00 and also 15 minutes b shows that workers are too eager to get the break and this reduces the concentr increase in no. of defects to 3, whereas average no of defects lie

r of defects

e trend is showing an increase in defects over the time. at 10:00, 11:45, 3:00 and 4:45. This time lies in 15 minute 2:00 and also 15 minutes before leave time of 5:00. This d this reduces the concentration of workers leading to as average no of defects lies around 1.

Age Absenteeism rate Temperature(F) Error Rate

24 6 65 1

30 5 63 2

22 7 72 0

25 6 66 0

33 4 82 3

27 5 58 3

36 4 75 1

58 1 86 5

37 3 77 2

47 2 65 1

54 2 79 3

Error Rate
6 5 4 3 2 1 0 0 20 40 60 80 100 8 7 6 5 4 3 2 1 0 0 10

Temperature(F)
Relationship between TEMPERATURE and ERROR RATE is parabolic As error rate decreases with increase in temperature, upto 66 F and then again starts rising from 72F onwards.

Absenteeism Rate

Error Rate

Relationship between AGE and As age increases, absenteeism r

28 5

42 3

55 1

Absenteeism rate

10

20

30

40

50

60

70

Age

ship between AGE and ABSETEEISM RATE is inverse. age increases, absenteeism rate decreases.

Part A Date Of Injuries By Department DEPART FALL EYE INJURY CUT/ABRASION SPORTS MOTOR VEHICLE No. of Injuries ADMIN 0 0 2 3 0 5 OPS 1 0 1 2 1 5 MAINT 7 3 5 16 9 40 SAFETY 0 0 1 1 1 3 TRAINING 0 1 0 1 2 4 57

% of total 8.771929825 8.771929825 70.1754386 5.263157895 7.01754386 100

Cumulative Percentage 9 # # # #