From:

To:

Date

Re:

Problem

There has been an increase in defects for tshirts.com. it is seen that this rate of
manufacturing defects is alarming. It can also be said that in order to detect this
error. Several steps have to be taken. The Problem has been analyzed and there are
different conclusions that can be proven.

Root Cause Analysis

There are different problems that can be made elaborative defects. The data in this
has certain characteristics. It can be seen that after computing the percentage
defects it can be seen that there are completely new solutions to the problem.

It can be seen that the employees all have consistency in their results

Employees
3.50%
3.00%
2.50%
2.00%
1.50%
1.00%
0.50%
0.00%
1111 2222 3333 4444 5555

It can be seen here that the employees have little variation and the employee, who
has the most error in this scenario. But the employee 4444 is been seen as the one
creating most defects in terms of percentage.
 Products
4.00%
3.50%
3.00%
2.50%
2.00%
1.50%
1.00%
0.50%
0.00%
10 20 30 50

When the second variable Products was analyzed, it was seen that the difference
was seen and it was significant. The most produced defects belonged to product 50.
Furthermore, it was also observed that the remaining products were better off.

Machines
4.00%
3.50%
3.00%
2.50%
2.00%
1.50%
1.00%
0.50%
0.00%
5 6 7 8

On observing the third variable it was seen that the machine also comprised of
primary differences that are significantly noticed in the above distribution. It can be
seen that the Machine 5 had most defects and this portrayed an approximate image
of the whole problem.

After this preliminary investigation was compiled, it was seen that the time for
combined factor analysis, to enable make appropriate distribution.
 5.00%
4.50%
4.00%
3.50%
3.00% 10
2.50% 20
2.00% 30
1.50% 50
1.00%
0.50%
0.00%
5 6 7 8

This chart highlights the machines on y axis and products as legend. It can be seen
that the highlighted machine 5 was correctly perceived and if it produced product
20. Further it can be seen that the machine 6 and 7 increases their defect rate of
product 50.

5.00%
4.50%
4.00%
3.50%
3.00% 5
2.50% 6
2.00% 7
1.50% 8
1.00%
0.50%
0.00%
10 20 30 50

Here the process has been reversed. Y axis portray products and legend highlights
machines. This highlighting depicts that Machine 5 is abnormal in product 20 and
the product 50 shows its abnormality in machine 6 and 7.

Solution

The presented graphs depict that either Machine 5 ought to be replaced, or it should
only be used to manufacture product 10. Furthermore, product 50 should be
produced by machine 8 and along with product 20 in order to reduce the defect
rate.

KPI Tracking

The KPI that ought to be the primary measure is the defect rate. This is the KPI, that
can be used to detect the abnormality and reduce defect rate.

Conclusion
The abnormality that was found can be concluded that the primary source of error
was in Machines and in Products. In order to minimize defect rate, an optimal
distribution of products and formidable composition with appropriate machines is
recommended.