Q - Using the data in the exhibits and the note on process control charts,

construct and analyze the appropriate SPC charts. What conclusions should
Rolfs draw?

Ans –

As per the data in Exhibit 3, centreline (which is the mean of all values) and range (is set at 3
standard deviations  )

POD WEIGHT
The X-Bar and R-Charts have been plotted according to data given in Exhibit 3 and we observe
that mean and range of Pod Weight lies within the Upper Control Limit (UCL) and Lower
Control Limits (LCL) on all shifts and days. Therefore, Pod Weight’s process is in control after
the implementation of Greenlight. We also observe that there is a continuous decline in the
last five readings. This raises an alarm and maintenance team should investigate for this
abrupt decline in the mean weight although it hasn’t reached the limit of 8.

Analysis of the shift based X-Bar charts reveals no identifiable patterns. Thus, the process is
under control and no action is required with respect to Pod Weight.
 X-Bar Chart : POD WEIGHT
2.85
2.84
2.83
2.82
2.81
2.8
2.79
2.78
2.77
2.76
2.75
2.74
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

X-Bar X-DoubleBar UCL LCL

R Chart : POD WEIGHT

0.160
0.140
0.120
0.100
0.080
0.060
0.040
0.020
0.000
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

Range R-Bar UCL LCL

FINGER HEIGHT
It’s clearly observed that Mean of Data (Finger Height) is above the limits on 19 shifts out of
45 as per the Data in Exhibit 3. It’s also evident that the variation in mean is quite high
between various shifts. One possible explanation for this may be due to the tweaking
equipment carried out by operators in an attempt to improve quality.
 X-Bar Finger Height - Shift A X-Bar Finger Height - Shift B
2.5 2.4

2.3 2.2

2.1 2

1.8
1.9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X-Bar X-DoubleBar UCL LCL
X-Bar X-DoubleBar UCL LCL

X-Bar Finger Height - Shift C

2.2

1.8

1.6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

X-Bar X-DoubleBar UCL LCL

As per the shift-based X-Bar charts shown below, it is observed that Shift A crossed Upper
Control Limit quite often but it never went below Lower Control Limit. Contrary to Shift A,
Shift C instead never crossed the Upper Control Limit. Instead it has gone below the Lower
Control Limit quite a few times. Hence it justifies the fact that there has been adjustments
made by the operations team.
Hence, we observe that Finger Height’s process is not in control and therefore, Rolfs needs
to carry out investigation to figure out the root cause of the issue. Operations team needs
to analyse the shift-based pattern and hence prove whether it’s due to the tweaking carried
out by the operator. And if the analyses reveal it to be true, then instructions needs to be
passed on to the operators to adopt strict adherence with respect to the process and call up
the technicians in case any issues come up.
One more suggestion is that the operators should record all the defects they find, the reason
being that equipment adjustments are done most of the time to correct these defects. In
absence of any record, it is not possible for the technician’s team to correctly recalibrate.