Trainee Name…………………..............

Kaizen basic №2
Exercise

1. You received a request for consulting from a factory regarding Kaizen in productivity. One of
typical labor-intensive section is a packaging process. Then you observed the workplace of
packaging process for around one hour and were awake that there were speedy workers and
slow workers. And you found that even speedy workers were sometimes slow. You are thinking
about investigation of the workplace, and analysis of problems and their causes. Please describe
why you choose each 7 QC tool and how you gather data.
QC7 tools Why you choose this 7 QC How you gather data?
tool?
Check sheet

Pareto chart

Cause and effect

diagram

Histogram

Scatter chart

Stratification

Control chart

2. The following table shows result of defect which occurred in the plastic molding process for
five days. Based on this data, please prepare Pareto chart. Unit loss amount is in the second

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column in the table. Please also prepare Pareto chart in value.

Figure of defect Birr 6th Mar. 7th 8th 9th 10th Total
Matte 25 14 8 12 10 12 56
Bubble 16 3 2 3 5 2 15
Foreign material 78 7 9 7 5 10 38
Swell 95 1 1 2 3 1 8
Graze 178 2 3 1 1 3 10
Stain 160 1 1 1 1 4
Crack 30 1 1 2
Blem 38 1 1 2
Asperity 65 1 1
Flow 20 1 1
Total 29 25 26 27 30 137

3. By use of cause and effect diagram, deploy measures to foster competent EKI consultants (or
TVET teachers) in providing direction for KAIZEN.

4. Data in the following table are gathered after random sampling of 100 parts from a lot made on
2, February and measuring diameter of the part. The diameter standard of this part is
81.00±2.55mm. Based on the data, prepare histogram and describe upper and lower limit of
standard on the graph.

Data on diameter of part

Unit: mm
79.2 79.9 82.3 80.5 81.2 81.2 80.2 80.4 80.6 79.9
79.8 78.4 81.1 79.9 79.7 81.2 80.4 80.0 80.1 80.0
79.6 79.0 80.1 80.8 80.4 79.9 80.1 82.1 79.9 80.2

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77.8 80.0 79.7 81.0 80.9 80.1 80.8 79.5 79.4 78.8
79.9 81.6 81.3 82.0 79.1 79.9 78.8 79.7 81.6 81.5
80.1 80.8 80.8 81.1 81.6 80.9 80.1 79.8 81.7 79.7
80.0 80.7 78.4 81.9 79.4 80.3 80.6 78.5 78.8 78.0
80.3 80.0 82.8 79.4 80.0 80.4 77.5 80.1 79.3 78.6
81.5 80.5 80.3 78.9 81.2 80.5 80.9 79.8 81.4 80.6
79.0 80.6 79.0 79.1 80.8 79.4 79.9 79.5 79.7 80.7
5. A bread plant divides dough by semi-automation machine. In purpose of leveling of dough
weight, they measure dough weight. To analyze by stratification, data are collected by workers
(A, B, C, D), machine (1, 2, 3) and weather (fair, clouded, rainy). Please prepare adequate
graphs and judge what criteria are effective for analysis. Request is to find the item that impact
on dough weight.

Weight(g) Worker Machine Weather Weight(g) Worker Machine Weather

77 B 3 Fair 74 D 1 Clouded
78 C 2 Rainy 80 C 3 Fair
76 D 2 Clouded 79 A 3 Rainy
73 A 1 Fair 74 D 1 Clouded
74 B 2 Rainy 80 A 3 Fair
78 D 3 Clouded 77 B 2 Rainy
75 C 2 Rainy 75 C 1 Rainy
76 B 1 Fair 81 D 3 Fair
73 D 1 Rainy 74 A 1 Clouded
79 C 3 Clouded 78 C 3 Rainy
76 A 1 Fair 76 B 2 Fair
75 B 2 Clouded 73 A 1 Clouded

6. For investigation of relationship between hardening temperature and hardness of steel, paired

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30 data in the table are collected. Based on the table, prepare scatter graph and describe what
relationship exists.
No. ℃ Hardness No. ℃ Hardness No. ℃ Hardness
1 810 47 11 840 52 21 810 44
2 890 56 12 870 53 22 850 53
3 850 48 13 830 51 23 880 54
4 840 45 14 830 45 24 880 57
5 850 54 15 820 46 25 840 50
6 890 59 16 820 48 26 880 54
7 870 50 17 860 55 27 830 46
8 860 51 18 870 55 28 860 52
9 810 42 19 830 49 29 860 50
10 820 53 20 820 44 30 840 49

7. Please select adequate description from the following three paired definitions of problem in
terms of Why-why analysis and mention its reason.

1. The screw was not tightened.

2. One of eight screws was not tightened.
Number of adequate description:　
Its reason:

1. A minor car accident occurred.

2. Car A and car B knock together.
Number of adequate description:　
Its reason:

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1. Temperature of oven does not rise.

2. Temperature of oven does not rise up to stated temperature.
Number of adequate description:　
Its reason:

8. Mention whether following deploying of Why-why analysis is adequate or not. If not,

complement necessary other “why”.

　　　　　Why　　　　　　　　　　　　　　　　　　　　Why
The cell-phone is not located
the The cell-phone was put in the
in habitual place. car.

The cell-phone was dropped

from breast pocket of jacket.