Case study:

QUALITY IMPROVEMENT USING

STATISTICAL PROCESS CONTROL
TOOLS IN GLASS BOTTLES
MANUFACTURING COMPANY

PRESENTING BY
V E N K AT E S H 16MBMA23
SRILEKHA 16MBMA28
SAI KIRAN 16MBMA38
RAHUL SONI 16MBMA48
ANU MALIK 16MBMA61
Intro
Seven basic quality control tools
Given by Kaoru Ishikawa, a renowned quality expert from Japan.
The seven quality tools are :
1. Check sheet,
2. Pareto chart,
3. Histogram,
4. Scatter diagram,
5. Process flow chart,
6. Cause-and-effect diagram or fish bone diagram,
7. Control charts
SPC Concept:
SPC is a statistical technique commonly used to control and reduce process
variation.
Philosophy- the output of a process can be brought into a state of statistical
control by means of management and engineering intervention.
SPCs strength lies in its ability to monitor both process centre and its
variation about that centre.
Adv is final inspection.
Emphasize on early detection and prevention of problems.
Aimed at continuously improving the process to manufacture quality
product for achieving high customer satisfaction.
Pareto chart
Data collected for number of visual defective (glass Data collected for number of physical defective (glass
bottles) over the past three months (January to March, bottles) over the past three months (January to
2011) March, 2011)
 Number of physical defective (glass
bottles) in descending order, relative
percentage and cumulative percentage
over the past three (January to March,
2011)

Data collected for number of physical defective

(glass bottles) over the past three months
(January to March, 2011)
 Pareto chart for types of physical
defects observed over the past
three months

Pareto chart for types of visual

defects observed over the past three
months
Brainstorming and Ishikawa diagram
 A technique used to elicit a large number of ideas from a team using
collective power

Happens in structural sessions in order to prevent distractions

Cause and effect diagram usually comes from Brainstorming

Optimal group (5-6 )members

FISH BONE DIAGRAM
Control chart
ECONOMIC ANALYSIS
IS machine average production capacity is 54 bottles per minute or
54*60=3240 glass bottles per hour.
percentage visual defective glass bottles is 13.74% and that of physical
defective is 27.08%, the average of the two is 20.41%.
Difference between average defective analyzed and company quality
acceptance level (20.41%-10%) is 10.41%.
Total Loss=3240*0.1*2.20 =712.8 Birr per hour.
Total loss from non-conforming glass bottles or defective glass bottles
was equal to 712.8*24*30*12 =6158592 Birr.
Contd
In March 2011, number of defective glass bottles due to pressure
failure defect was 1350 glass bottles and in month of April 2011,
number of defective glass bottles reduced to 778 .
572 glass bottles were saved per month only from defective caused by
pressure failure.
March 2011, the number of defectives glass bottles were 181 and it
came reduced to 170 glass bottles as a result an improvement of 11
glass bottles indicated
The total gain annually due to reduction inpressure failure is
583*2.20*12=15391.2 Birr
Results and discussions
Summary
Production line is out of use, over usage of molds and molding blocks
resulted in defective products and inefficiency.
Although the company has many constraints to implement all
suggestion for improvement within short period of time, the company
recognized that the suggestion provided will bring significant
productivity improvement in the long run.
Study resulted in designing the use of SPC tools. The resulting analysis
leads to operating procedures that significantly reducing rejections and
rework due to defective glass bottles.
Conclusion
SPC tools provided the useful information in identifying causes for rejection,
remedies and in proposing optimal solution.
The main contributors to the rejection, main factors for these defects are
identified.
Old machinery, furnace, raw material preparation have many problems.
Lack of management involvement, improper production processes, lack of
training to implement SPC, improper maintenance of machinery.
Implementation of SPC tools at the company is expected to improve its processes
and reduce variability.
Quality control chart is an effective statistical technique for locating any trouble
or variation.
Thank you