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Practice

Carton Manufacturing Defects
Line 1 Line 2 Line 3 Total Defects Instructions
Bent/Damaged flaps 37 22 24 83 1. Select cells A2:A14,E2:E14 using your mouse (CTRL to select second column)
Carton will not open 29 18 29 76 2. Click on Pareto Chart
Damaged Pallet 3 3 3. Review the Pareto chart - Folded Flaps is the most common problem
Fisheye 9 9 4. Come back to this sheet and select A2:E14 and run the Pareto Chart
Folded flaps 16 6 83 105 5. Open your own data and run a Pareto Chart
Ink smears/streaks 5 19 24
Mislabeled 3 3
Missing color 8 8
Off color 14 5 12 31
Oil spots 14 14
Poor ink adhesion 7 8 18 33
Undercount 2 2

Pareto Chart Practice and Application

Manufacturing

Carton Manufacturing Defects (Quality Digest Dec 2006) Lost Time Analysis (LTA) Description Scrapped Qty Ship Qty Scrap % of Shipped Tank Defects
Line 1 Line 2 Line 3 Total Defects Lost Time (Minutes) Support 169 2000 8.45% Incorrect Dimensions 36
Folded flaps 16 6 83 105 Generator Failure 346 Poppet 78 2000 3.90% Parts damaged 34
Bent/Damaged flaps 37 22 24 83 Conveyor Failure 71 Core 135 3500 3.86% Machining 29
Carton will not open 29 18 29 76 Training 34 Stainless Body 64 2486 2.57% Insufficient masking 17
Poor ink adhesion 7 8 18 33 Safety 26 Solid Top Axle 4 197 2.03% Parts rusted 13
Off color 14 5 12 31 Flooding 20 Armature 93 5000 1.86% Adhesive failure 6
Ink smears/streaks 5 19 24 Pump Failure 9 Aluminum Washer 76 4970 1.53% Film on parts 5
Oil spots 14 14 Flange 34 2300 1.48% Salt spray failure 4
Fisheye 9 9 Causes of Lost Time Incidences Safety Plug 56 4000 1.40% Out of order 4
Missing color 8 8 Work Instructions 45 Neck 1 79 1.27% unfinished fairing 3
Mislabeled 3 3 Bill of Materials 40 Stainless Washer 11 1037 1.06% Wrong part issued 3
Damaged Pallet 3 3 Work Orders 30 Terminal Cap #8 10 1065 0.94% Weld misaligned 2
Undercount 2 2 Out of Stock 7 Barrel 18 2148 0.84% Paint out of spec 2
Wrong parts or material 7 Terminal Cap #10 12 1955 0.61% Delaminated composit 2
Circuit Board Defects Lack of tools 7 G30 Front Wearplate 3 500 0.60% Voides in casting 2
Bad 8 Bad assembly 7 Low Profile Housing 1 215 0.47% Paint damaged 1
Bridge 1 Solid Body 1 303 0.33% Primer damaged 1
Damage 6 Service Order Rejects Lost Time Stainless Washer 2 1060 0.19% improper procedure 1
Excess 3 Location 1 7564 630 G20 Wearplate 3 5046 0.06% powdery alodine 1
Extra 1 Location 2 13618 106 Stainless Washer 1 2070 0.05%
Insult 9 Location 3 2121 37
Lifted Lead 5 Location 4 5121 293 Defectives Guide to Quality Control (Ishikawa)
Missing 6 Location 5 6341 288 Caulking 198
Open 2 Location 6 7116 710 Fitting 25
Orient 2 Location 7 5212 516 Connecting 102
Poor Wetting 1 Location 8 16447 654 Torque 18
Solder ball 2 Location 9 6530 504 Gapping 72
TH Void 16
Install Replace Adjust Lube Total
Door 2 5 1 0 8
Motor 2 1 11 6 20
Track 1 0 6 4 11
Vinyl 11 1 0 0 12
T-Lock 9 0 1 0 10
Total 25 7 19 10 61

Service

Restaurant Complaints Number Lean Six Sigma
Cold Food 105 Donna Summers
Flimsy Utensils 20 pg 97
Food tastes bad 10
Salad Not Fresh 94
Poor Service 15
Food Greasy 9
Lack of Courtesy 5
Lack of Cleanliness 25
Bank Call Center Calls
Credit Card Payment Questions 245
Transfer Call 145
Balance Questions 377
Payment Receipt Questions 57
Finance Charge Questions 30
Other 341

Healthcare

Claim Denied (No Appeal) Medication Errors Baseline Medication Errors 6 months Medication Errors 18 months Lab Order Errors Type of test Quantity Adverse Events Medication management New Medications Effects of surgery Effects of tests Other Prescribing Errors
Timely Filing $ 7,849,569 Wrong Technique 41 25 5 SSN 226 Chemistry 22063 infection 0 0 38 6 7 Allergy Related 55
Medical Necessity $ 2,516,508 Wrong Time 33 13 16 Name 71 Hematology 5532 Injury 0 3 84 6 3 Ambiguous Order 5
No Authorization $ 1,295,032 Wrong Dose 5 1 2 DOB 58 Urine 2292 Mycardial infarction 0 0 9 2 7 Delayed Treatment 3
Partial Authorization $ 750,766 Wrong Route 5 1 0 Test 44 Serology 1043 Deep vein thrombosis 1 0 9 1 1 Duplicate Additive (TPN) 18
Invalid Auth for Patient Status $ 336,270 Drug not available 3 5 4 Doctor 39 Bacteriology 673 Fall 1 0 3 1 11 Dupliate Order 13
Wrong Form 3 0 0 Other 16 Pressure Sores 0 0 6 0 7 Duplicate Therapy 12
Surgical Retained Foreign Objects # RFOs Extra Dose 1 3 2 Rash 0 71 3 5 13 Illegible 16
Sponges 23 Unauthoried Drug 0 2 1 Breathing Problems 1 7 18 0 8 Incomplete (TPN and chemotherapy) 174
Instrument 1 Omission 0 2 0 Confusion 1 27 3 0 0 Incomplete other 7
Needles 3 Dizziness 1 40 0 0 1 Ion implance (TPN) 25
Miscellaneous 7 Drop in Blood Pressure 3 25 23 3 9 Overfill (TPN) 53
Nausea 2 70 0 5 0 Rate/volume (TPN) 35
Pharmacy Order Entry Errors Type of Wrong Site or Patient Surgery Missing Billing Coding and Info Pain 9 0 9 7 3 Unnecessary dose or medication 7
Order not received 51 Orthopedic Surgery 52 Joint Commission Dec 5, 2001 Pharmacy 76 Other responses 37 91 0 6 1 Unordered medication 29
Wrong Frequency of Dose 47 General Surgery 25 Diagnosis 12 Other events 0 3 84 30 20 unstable 60
Duplicate order entry 20 Neurosurgery 18 Treatment charge 11 total 56 337 289 72 91 Wrong calculation 11
Wrong Dose 20 Urologic Surgery 13 Account type 6 Wrong concentration 17
Omission Drug 19 Other 18 Venipuncture 5 Patient Reported Errors Wrong Dose 355
Order not Discontinued 13 Other 6 Medical Error 26 Wrong dose of additive 30
Additional Instructions 13 Wrong Site or Patient Surgery Pharmacy 12 Wrong drug 28
Wrong Drug 11 Wrong Body Part or Site 96 Joint Commission Dec 5, 2001 Clinician 14 Wrong drug Additive 3
Wrong Patient 3 Wrong Patient Surgery 17 Nonmedical Error 22 Wrong duration of therapy 9
Wrong Route (IV vs Intramuscular) 2 Wrong Procedure 13 Insurance or billing 7 Wrong dosage form 59
Drug Use Volumne and costs Scheduling 6 Wrong Frequency 81
Missed Start Times in Cath Lab Wrong Site or Patient Surgery Drug Cost/unit Units Used Total Cost ($000) Wrong Information 6 Wrong Patient 10
Room Not Read 43 wrong patient 34 A 180 361 65 Prescription Delay 2 Wrong rate ofinfusion 9
Doctor Not Ready 88 wrong procedure 39 B 250 160 40 Test results delay 1 Wrong Route of adminsitration 22
Prior Procedure Too Long 47 wrong side 298 C 950 347 330 Behaviour/Communication 49 Wrong Schedule 40
Prior Case Add On 26 wrong part (60) 60 D 90 389 35 Waiting time 18 Wrong volume 4
Prior Case Too Early 84 E 75 267 20 Clinician disrespect 11 Wrong weight 6
Case Start Early 19 F 560 89 50 Staff disrespect 8
G 1350 11 15 Felt rushed 4
NJ Impact of Adverse Events Adverse Event Patient falls in New Jersey Hospitals H 650 169 110 Technician care 2
Additional laboratory testing 283 NJ 2007 Falls 2005 Falls 2006 Falls 2007 I 220 114 25 Other 6
Additional patient monitoring 270 Patient Room 103 132 152 J 15 1333 20 Misunderstanding 112
Physical disability or mental impairment 185 Hallway 6 12 14 K 56 1518 85 Medical Care 71
Increased length of stay 183 Emergency Department 8 12 12 L 150 1367 205 Medication side effects 15
Major surgery 121 Radiology 1 3 4 Clinician unhelpful 11
Transfer to higher level of care 91 ICU/CCU/TCU 1 3 4 Scheduling 7
Death 72 Telemetry Unit 1 0 4 Ordering 4
Minor surgery 53 Cardiac Catheterization Laboratory 0 2 2 Insurance Coverage 3
Other additional testing 38 Rehabilitation Areas 1 2 2 Missing documentation 1
System/process delay 38 Other 3 2 2
To be determined 35
Hospital admission 23
Loss of bodily function 13
Other 13
Loss of sensory function 10
Loss of organ 4

Text

Defect <-- Click the heading and then click Pareto Chart
Bent/Damaged flaps
Carton will not open
Folded flaps
Folded flaps
Off color
Bent/Damaged flaps
Carton will not open
Bent/Damaged flaps
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Ink smears/streaks
Folded flaps
Carton will not open
Carton will not open
Poor ink adhesion
Carton will not open
Off color
Bent/Damaged flaps
Carton will not open
Carton will not open
Folded flaps
Poor ink adhesion
Poor ink adhesion
Ink smears/streaks
Folded flaps
Poor ink adhesion
Carton will not open
Folded flaps
Bent/Damaged flaps
Carton will not open
Folded flaps
Poor ink adhesion
Off color
Carton will not open
Off color
Carton will not open
Folded flaps
Bent/Damaged flaps
Carton will not open
Bent/Damaged flaps
Carton will not open
Poor ink adhesion
Folded flaps
Carton will not open
Poor ink adhesion
Poor ink adhesion
Bent/Damaged flaps
Oil spots
Folded flaps
Folded flaps
Folded flaps
Carton will not open
Folded flaps
Off color
Carton will not open
Bent/Damaged flaps
Bent/Damaged flaps
Carton will not open
Folded flaps
Off color
Carton will not open
Carton will not open
Bent/Damaged flaps
Off color
Poor ink adhesion
Bent/Damaged flaps
Poor ink adhesion
Folded flaps
Bent/Damaged flaps
Folded flaps
Fisheye
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Folded flaps
Carton will not open
Off color
Poor ink adhesion
Fisheye
Folded flaps
Poor ink adhesion
Carton will not open
Carton will not open
Folded flaps
Bent/Damaged flaps
Carton will not open
Missing color
Bent/Damaged flaps
Folded flaps
Poor ink adhesion
Bent/Damaged flaps
Carton will not open
Carton will not open
Off color
Bent/Damaged flaps
Folded flaps
Fisheye
Folded flaps
Folded flaps
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Ink smears/streaks
Folded flaps
Folded flaps
Folded flaps
Poor ink adhesion
Folded flaps
Folded flaps
Folded flaps
Bent/Damaged flaps
Folded flaps
Off color
Folded flaps
Bent/Damaged flaps
Poor ink adhesion
Folded flaps
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Oil spots
Bent/Damaged flaps
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Oil spots
Folded flaps
Folded flaps
Carton will not open
Bent/Damaged flaps
Bent/Damaged flaps
Oil spots
Bent/Damaged flaps
Bent/Damaged flaps
Ink smears/streaks
Carton will not open
Folded flaps
Carton will not open
Poor ink adhesion
Folded flaps
Ink smears/streaks
Folded flaps
Carton will not open
Fisheye
Ink smears/streaks
Off color
Poor ink adhesion
Poor ink adhesion
Bent/Damaged flaps
Carton will not open
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Poor ink adhesion
Carton will not open
Carton will not open
Ink smears/streaks
Folded flaps
Ink smears/streaks
Carton will not open
Ink smears/streaks
Carton will not open
Folded flaps
Poor ink adhesion
Folded flaps
Carton will not open
Carton will not open
Off color
Poor ink adhesion
Poor ink adhesion
Mislabeled
Off color
Fisheye
Ink smears/streaks
Folded flaps
Folded flaps
Carton will not open
Oil spots
Ink smears/streaks
Ink smears/streaks
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Carton will not open
Undercount
Carton will not open
Oil spots
Bent/Damaged flaps
Carton will not open
Off color
Oil spots
Bent/Damaged flaps
Carton will not open
Folded flaps
Ink smears/streaks
Folded flaps
Mislabeled
Oil spots
Folded flaps
Bent/Damaged flaps
Carton will not open
Folded flaps
Carton will not open
Folded flaps
Poor ink adhesion
Missing color
Folded flaps
Off color
Folded flaps
Folded flaps
Missing color
Off color
Ink smears/streaks
Ink smears/streaks
Carton will not open
Poor ink adhesion
Carton will not open
Bent/Damaged flaps
Ink smears/streaks
Bent/Damaged flaps
Folded flaps
Folded flaps
Carton will not open
Folded flaps
Carton will not open
Off color
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Mislabeled
Folded flaps
Carton will not open
Bent/Damaged flaps
Fisheye
Bent/Damaged flaps
Off color
Carton will not open
Off color
Carton will not open
Bent/Damaged flaps
Off color
Oil spots
Carton will not open
Folded flaps
Folded flaps
Off color
Folded flaps
Bent/Damaged flaps
Carton will not open
Fisheye
Bent/Damaged flaps
Folded flaps
Bent/Damaged flaps
Off color
Bent/Damaged flaps
Off color
Off color
Bent/Damaged flaps
Off color
Missing color
Bent/Damaged flaps
Missing color
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Carton will not open
Off color
Carton will not open
Folded flaps
Folded flaps
Damaged Pallet
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Ink smears/streaks
Missing color
Carton will not open
Folded flaps
Bent/Damaged flaps
Off color
Oil spots
Carton will not open
Bent/Damaged flaps
Folded flaps
Bent/Damaged flaps
Poor ink adhesion
Carton will not open
Oil spots
Missing color
Bent/Damaged flaps
Bent/Damaged flaps
Damaged Pallet
Folded flaps
Folded flaps
Carton will not open
Bent/Damaged flaps
Carton will not open
Folded flaps
Folded flaps
Folded flaps
Folded flaps
Off color
Folded flaps
Folded flaps
Off color
Bent/Damaged flaps
Off color
Folded flaps
Bent/Damaged flaps
Fisheye
Carton will not open
Carton will not open
Folded flaps
Bent/Damaged flaps
Poor ink adhesion
Carton will not open
Carton will not open
Undercount
Poor ink adhesion
Poor ink adhesion
Carton will not open
Carton will not open
Oil spots
Poor ink adhesion
Oil spots
Bent/Damaged flaps
Folded flaps
Folded flaps
Folded flaps
Folded flaps
Missing color
Folded flaps
Ink smears/streaks
Carton will not open
Carton will not open
Ink smears/streaks
Folded flaps
Carton will not open
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Folded flaps
Bent/Damaged flaps
Carton will not open
Bent/Damaged flaps
Bent/Damaged flaps
Poor ink adhesion
Bent/Damaged flaps
Carton will not open
Carton will not open
Folded flaps
Poor ink adhesion
Carton will not open
Poor ink adhesion
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Poor ink adhesion
Folded flaps
Folded flaps
Folded flaps
Fisheye
Bent/Damaged flaps
Carton will not open
Folded flaps
Folded flaps
Folded flaps
Folded flaps
Bent/Damaged flaps
Carton will not open
Ink smears/streaks
Bent/Damaged flaps
Off color
Folded flaps
Carton will not open
Bent/Damaged flaps
Folded flaps
Carton will not open
Folded flaps
Damaged Pallet
Folded flaps
Folded flaps
Oil spots

Auto Seat Cushion Defects

Inspection Report of auto seat cushions Date Auto Seat Cushion Defects
Kind of Defect 12-Aug 13-Aug 14-Aug 15-Aug 16-Aug Total Seat Cushion Defects 12-Aug Poor Mix
Poor Mix 2 3 1 6 12-Aug Poor Mix
Holes 8 4 7 3 22 14-Aug Poor Mix
Dent 1 5 6 14-Aug Poor Mix
Not enough component 1 1 2 14-Aug Poor Mix
Deformed 1 1 15-Aug Poor Mix
Torn through handling 1 1 2 12-Aug Holes
Oil/grease stains 1 1 1 3 12-Aug Holes
12-Aug Holes
12-Aug Holes
12-Aug Holes
12-Aug Holes
12-Aug Holes
12-Aug Holes
13-Aug Holes
13-Aug Holes
13-Aug Holes
13-Aug Holes
14-Aug Holes
14-Aug Holes
14-Aug Holes
14-Aug Holes
14-Aug Holes
14-Aug Holes
14-Aug Holes
15-Aug Holes
15-Aug Holes
15-Aug Holes
13-Aug Dent
16-Aug Dent
16-Aug Dent
16-Aug Dent
16-Aug Dent
16-Aug Dent
12-Aug Not enough component
14-Aug Not enough component
16-Aug Deformed
12-Aug Torn through handling
15-Aug Torn through handling
13-Aug Oil/grease stains
14-Aug Oil/grease stains
15-Aug Oil/grease stains

Hose Assembly Defects

Defects 1st shift 2nd shift 3rd shift Total 10.1% of hose assemblies are defective SPC Simplified, Quality Resources, 1989
Too Short 30 35 26 91 Leadership thinks it's a shift issue.
Too long 44 44 44 132 What issues should be addressed?
Missing threads 10 69 70 149
Leaks 330 321 347 998
Damaged 8 11 5 24
Other 22 20 13 55
Total 444 500 505
O.K. 4508 4495 4481 13484

Billing

Billing Error Number
Incorrect amount 12
Wrong Customer 3
Boulble billing 4
Billing for Unordered Goods 16
Late Billing 5

Software

Symptom
Abnormal End 5
Address Error 5
Incorrect Output 53
Infinite Loop 9
Error Message 0
Endless Wait 29
Customer Affecting Software Errors
Allocation Mgt 31
Copying Overrun 13
Pointer Mgt 16
Register Reused 6
Uninitialized Ptr 12
Type Mismatch 10
Undefined State 0
Unknown 0
Synchronization 12
Error Requires Reboot
Boundary Condition 4
Bug Fix 3
Customer Code 0
Recovery 31
No Trigger 0
Timing 59
Unknown 3
Software Engineering Activities Days (Source: Capers Jones)
Testing & Repair 70
Y2K like repairs 50
Cancelled Projects 30
Productive time on projects 47
Defects/Function Point
Requirements 1.00
Design 1.25
Code 1.75
User manuals 0.60
Bad Fixes 0.40

Accident

Accidents by Department Accidents by Category
A 5 1 4 Data Sanity, Davis Balestracci
B 29 2 2
C 7 3 19
D 3 4 1
E 35 5 13
F 7 6 3
7 7
8 1
9 1
10 5
11 1
13 1
15 6
17 1
18 2
21 5
24 3
26 2

Government

NASA Expenditures
Orbiter and Integration 724.5
External Tank 349.7
Main Engine 261.9
Reusable Solid Rocket Motor 418.3
Solid Rocket Booster 137.5
Mission Launch Operations 780.9