Name: Ameer Hamza Registration No.
: 20JZMEC0389
➢ Objective:
To identify the imperfections in the processes and its causes of any industry and then
represent it using SPC tools.
Evaluating Defects in Manufacturing Process
➢ Company Name:
DYNEA PAKISTAN LIMITED (Gadoon Unit).
➢ Company Introduction:
Dynea Pakistan Limited (the Company) was incorporated in Pakistan as a public limited
company, under the repealed Companies Act 1913 (now the Companies Act, 2017) on 20
June, 1982 and is listed on the Pakistan Stock Exchange Limited. Dynea Pakistan is a leading
manufacturer of adhesive and surfacing solutions. The company is engaged in the production and
sale of formaldehyde, urea and melamine formaldehyde resins and adhesives, moulding compounds
glazing powder and tableware. Moulding compound and glazing powder have a wide variety of
applications for use in wood-based panels, decorative surfaces and tableware.
➢ Defects in manufacturing of tableware:
Defect of tableware are listed below
• Air Bubbles.
• Surface Cracks
• Holes Inside
• Stick to Mould
• Stains
• White Spots
• Small Wrinkles
➢ SPC Tools:
SPC tools refer to Statistical Process Control tools, which are a set of techniques and
methods used in quality control and process improvement. The primary purpose of SPC
tools is to monitor and control the variation in a process, ensuring that it operates within
predefined limits and meets quality standards consistently.
Here are some commonly used SPC tools:
Name: Ameer Hamza Registration No.: 20JZMEC0389
1. Control Charts:
Control charts are graphical representations that track process data over time. They help
identify patterns, trends, and abnormal variations in the process. Control charts include
different types like the X-bar and R charts, X-bar and S charts, and individuals (I-MR)
charts.
2. Histograms:
Histograms are graphical representations that display the distribution of a process
variable. They provide insights into the shape, center, and spread of the data, helping to
assess process capability and identify potential issues.
3. Pareto Charts:
Pareto charts are bar graphs that rank issues or problems in descending order of their
frequency or impact. They enable prioritization by focusing on the most significant factors
contributing to process variation.
4. Cause-and-Effect (Fishbone) Diagrams:
Fishbone diagrams are visual tools used to identify and organize potential causes
leading to a particular problem or outcome. They help analyze root causes across different
categories, such as people, methods, materials, machines, measurements, and environment
(the 5 M's + E).
5. Scatter Plots:
Scatter plots display the relationship between two variables to identify patterns or
correlations. They are useful in analyzing cause-and-effect relationships and identifying
potential sources of variation.
6. Process Capability Analysis:
Process capability analysis determines the ability of a process to consistently produce
output within predefined specifications. It involves statistical calculations like Cp, Cpk, Pp,
and Ppk, which assess the process performance and capability.
7. Run Charts:
Run charts are line graphs that display process data over time. They help visualize
process performance, detect trends, and assess the stability of the process.
8. Statistical Analysis:
Various statistical techniques, such as hypothesis testing, regression analysis, and
analysis of variance (ANOVA), are employed in SPC to analyze data, validate
improvements, and make data-driven decisions.
These SPC tools enable organizations to monitor, control, and improve their processes,
leading to enhanced quality, reduced waste, and increased customer satisfaction.
Name: Ameer Hamza Registration No.: 20JZMEC0389
➢ Applying SPC tools:
In our case only three SPC tools can be applied:
1. Process Flow Chart.
2. Pareto diagram.
3. Cause and effect diagram.
1. Process Flow Chart:
A schematic diagram is a visual representation that shows how a product or service
moves through different stages of processing. It helps us easily see the entire system, find
areas that might cause problems, and locate specific tasks. It also helps teams come to an
agreement on the steps involved in the process and identify activities that could affect
performance. In simple terms, it's like a map that helps us understand how things are done
and where things could go wrong in a process.
➢ Process flow chart of the problem is given below:
Name: Ameer Hamza Registration No.: 20JZMEC0389
START
Measure Samples
Record Data on Chart
Compare Individual
Reading to specification
All Readings with
in Specifications
Yes
Yes
Compare Plot Points to
Control Limits
No
In Control
Yes
End
Name: Ameer Hamza Registration No.: 20JZMEC0389
2. Pareto Diagram:
A Pareto chart is a type of bar graph that helps us decide which problems to solve first
and in what order. The length of each bar in the graph represents how frequently a problem
occurs or how much it costs (in terms of time or money). The bars are arranged from longest
to shortest, showing us visually which issues are the most significant. This tool is
commonly used to analyze causes and is considered one of the seven fundamental tools for
quality improvement. In simpler terms, it's a graph that helps us prioritize problems based
on their frequency or impact.
➢ Steps of construction of Pareto chart:
Following are the steps for the construction of Pareto Diagram;
i. Determine method of classifying data.
ii. Decide frequency is to be used to rank characteristics.
iii. Collect date for an appropriate time interval.
iv. Summarize data and rank from largest to smallest.
v. Compute the cumulative percentage.
vi. Construct the diagram.
Data for the Defects in the Process
Defects Frequency
Air bubbles 10
Small wrinkles 8
White Spots 4
Holes inside 5
Stains 6
Stick to mould 2
Surface crack 17
➢ Calculations and Construction:
Calculation and construction of Pareto charts is given below (Made in excel).
Name: Ameer Hamza Registration No.: 20JZMEC0389
Defects Frequency Cumulative Cumulative
Frequency Percentage
Surface Cracks 17 17 33%
Air Bubbles 10 27 52%
Small Wrinkles 8 35 67%
Stains 6 41 79%
Holes Inside 5 46 88%
White Spots 4 50 96%
Stick to Mould 2 52 100%
∑ f = 52 ∑ Cf = 268
Pareto Diagram
3. Cause and Effect Diagram:
A cause-effect diagram, also known as a fishbone or Ishikawa diagram, is a visual tool
used to organize possible causes for a specific problem or effect. It helps to identify the
root causes by displaying them in increasing detail and showing possible relationships
among different theories. It can be created as a fishbone diagram or a tree diagram.
When trying to figure out the cause of a problem, a cause-effect diagram helps to
structure and present various theories about the root causes in a graphical way. The cause-
effect diagram is commonly used in the early stages of an improvement team's work. It is
Name: Ameer Hamza Registration No.: 20JZMEC0389
populated with ideas generated during brainstorming or affinity processes. Since the list of
issues on a cause-effect diagram can be extensive, the team should use techniques like
prioritization or multi-voting to narrow down the potential causes they want to investigate
further. The main part of the diagram is the "Effect" that the team is investigating. The team
brainstorms and lists potential causes for this effect. These potential causes become the
branches of the diagram, and the headers represent the categories or themes identified in
the affinity diagram.
➢ Key Concepts of Fishbone Diagram:
• A cause-effect diagram does not find the exact root cause of a problem, but it
visually presents the various causes that could contribute to the observed effect. It
is a way to visually represent the factors that might be involved in the effect being
examined.
• The diagram clearly shows how the possible causes are related to each other. One
cause may appear in multiple places on the diagram. The diagram helps to focus the
attention of all team members on the specific problem in a structured and organized
manner.
➢ Cause and Effect Diagram of Problem is Given Below:
Name: Ameer Hamza Registration No.: 20JZMEC0389
➢ Solutions of the Problems:
1. Workers need better training:
The workers should receive appropriate training to improve their skills and
knowledge.
2. Use advanced machines:
Installing new and modern technology machines can help improve efficiency
and productivity.
3. Increase the number of workers in shifts:
Adding more workers to each shift can alleviate workload and enhance
productivity.
4. Have more inspection staff:
Hiring additional staff for inspections can help identify and address quality
issues more effectively.
5. Obtain new and high-quality measurement tools:
Investing in new and reliable measurement tools can ensure accurate
measurements and good quality control.
6. Use good quality raw materials:
Using high-quality raw materials can lead to better overall product quality and
performance.
These causes highlight the potential areas of improvement that can contribute
to resolving the problem or achieving the desired effect.
THE END
