Overall performance of Receiving process

Proportion Proportion
Slotter of slotter Keying Letdown of Let down ITR ADJ
Date
errors error errors errors error errors
defectives defectives

1-Jun 4 0.005 1 1 0.00125 1

2-Jun 11 0.01375 2 1 0.00125 2
3-Jun 11 0.01375 2 0 0 2
4-Jun 6 0.0075 6 0 0 0
5-Jun 6 0.0075 0 0 0 1
6-Jun 19 0.02375 0 0 0 0
7-Jun 11 0.01375 0 0 0 0
8-Jun 3 0.00375 1 2 0.0025 0
9-Jun 3 0.00375 0 3 0.00375 0
10-Jun 3 0.00375 0 3 0.00375 0
11-Jun 5 0.00625 0 3 0.00375 0
12-Jun 0 0 1 1 0.00125 0
13-Jun 4 0.005 1 3 0.00375 0
14-Jun 2 0.0025 0 2 0.0025 0
15-Jun 0 0 2 2 0.0025 0
16-Jun 2 0.0025 2 0 0 0
17-Jun 4 0.005 0 1 0.00125 0
18-Jun 3 0.00375 1 4 0.005 2
19-Jun 4 0.005 0 3 0.00375 0
20-Jun 7 0.00875 2 2 0.0025 0
21-Jun 13 0.01625 0 2 0.0025 0
22-Jun 7 0.00875 0 2 0.0025 0
23-Jun 4 0.005 0 4 0.005 0
24-Jun 7 0.00875 0 0 0 0
25-Jun 2 0.0025 0 1 0.00125 0
26-Jun 2 0.0025 0 1 0.00125 0
27-Jun 2 0.0025 0 2 0.0025 0
28-Jun 8 0.01 1 1 0.00125 0
29-Jun 7 0.00875 1 1 0.00125 0
30-Jun 1 0.00125 1 1 0.00125 0
1-Jul 10 0.0125 0 2 0.0025 0
2-Jul 7 0.00875 0 2 0.0025 0
3-Jul 4 0.005 0 1 0.00125 0
4-Jul 6 0.0075 0 2 0.0025 0
5-Jul 3 0.00375 0 1 0.00125 0
6-Jul 0 0 2 2 0.0025 0
7-Jul 1 0.00125 0 5 0.00625 0
8-Jul 5 0.00625 0 2 0.0025 0
9-Jul 5 0.00625 2 2 0.0025 0
10-Jul 6 0.0075 0 0 0 0
11-Jul 9 0.01125 0 3 0.00375 0
12-Jul 9 0.01125 0 3 0.00375 0
13-Jul 4 0.005 0 2 0.0025 0
14-Jul 0 0 0 3 0.00375 0
15-Jul 0 0 0 2 0.0025 0
230 0.2875 28 78 0.0975 8
ance of Receiving process

Putaway Total Slots Proportion In/Out of

Other errors Total errors
errors checked defectives control

0 3 10 800 0.0125 in control

2 7 25 800 0.0313 in control
4 4 23 800 0.0288 in control
2 11 25 800 0.0313 in control
3 4 14 800 0.0175 in control
1 5 25 800 0.0313 in control
2 2 15 800 0.0188 in control
1 16 23 800 0.0288 in control
1 3 10 800 0.0125 in control
0 5 11 800 0.0138 in control
0 7 15 800 0.0188 in control
1 22 25 800 0.0313 in control
4 5 17 800 0.0213 in control
0 19 23 800 0.0288 in control
0 1 5 800 0.0063 in control
1 0 5 800 0.0063 in control
2 0 7 800 0.0088 in control
0 0 10 800 0.0125 in control
2 1 10 800 0.0125 in control
3 3 17 800 0.0213 in control
1 9 25 800 0.0313 in control
2 5 16 800 0.0200 in control
1 6 15 800 0.0188 in control
2 7 16 800 0.0200 in control
4 2 9 800 0.0113 in control
4 1 8 800 0.0100 in control
0 8 12 800 0.0150 in control
0 6 16 800 0.0200 in control
0 7 16 800 0.0200 in control
1 4 8 800 0.0100 in control
1 8 21 800 0.0263 in control
2 4 15 800 0.0188 in control
6 1 12 800 0.0150 in control
1 1 10 800 0.0125 in control
0 2 6 800 0.0075 in control
0 1 5 800 0.0063 in control
0 19 25 800 0.0313 in control
0 3 10 800 0.0125 in control
1 6 16 800 0.0200 in control
1 2 9 800 0.0113 in control
0 8 20 800 0.0250 in control
0 8 20 800 0.0250 in control
5 0 11 800 0.0138 in control
8 1 12 800 0.0150 in control
0 5 7 800 0.0088 in control
69 242 655 36000 0.0182
Control limits
Average Proportion defective 0.0182
SD for a sample of size 800 0.00472538
Upper Control limit 0.0324
Lower Control Limit 0.0040

Control limits- Slotter Erros

Average Proportion defective 0.2875
SD for a sample of size 800 0.01600171
Upper Control limit 0.3355
Lower Control Limit -0.0480

Proportio
0.007
0.006
0.005
0.004
0.003
0.002
0.001
0
2-Jun 4-Jun 6-Jun 8-Jun 10-Jun 12-Jun 14-Jun 16-Ju
1-Jun 3-Jun 5-Jun 7-Jun 9-Jun 11-Jun 13-Jun 15-Jun 1
 Control Limits- let down error
Average Proportion defective 0.0975
SD for a sample of size 800 0.01048772
Upper Control limit 0.1290 0.025
Lower Control Limit -0.0315 Proportion

0.02

Proportion of Let down error

0.015
defectives

0.01

0.005

0
2-Jun 4-Jun
n 10-Jun 12-Jun 14-Jun 16-Jun 18-Jun 20-Jun 22-Jun 24-Jun 26-Jun 28-Jun 30-Jun 6-Jun
2-Jul 8-Jun
4-Jul10-Jun 12-Jun
6-Jul 14-Jun
8-Jul 16-
10-Jul
1-Jun 3-Jun
9-Jun 11-Jun 13-Jun 15-Jun 17-Jun 19-Jun 21-Jun 23-Jun 25-Jun 27-Jun 29-Jun 5-Jun
1-Jul 7-Jun
3-Jul 9-Jun
5-Jul11-Jun 13-Jun
7-Jul 15-Jun
9-Jul 11
 Run Chart- Proportion defectives

3-Jun 7-Jun 11-Jun 15-Jun 19-Jun 23-Jun 27-Jun 1-Jul 5-Jul

1-Jun 5-Jun 9-Jun 13-Jun 17-Jun 21-Jun 25-Jun 29-Jun 3-Jul
efectives UCL=0.0324
Overall receiving proce

UCL=0.0040

27-Jun 1-Jul 5-Jul 9-Jul 13-Jul

n 29-Jun 3-Jul 7-Jul 11-Jul 15-Jul
Overall receiving process is in control
Receiving process errors should not
exceed 2% on any day
From normal distribution table,
z= 2.06
Mean and standard deviation is
calculated in previous sheet and
hence,
x= 3%

% of days likely to exceed 2% error is 3%

Errors Receiving Module 1 Module 3
Other errors 242 158 84
Slotter error 230 164 66
Letdown error 78 77 1
Putaway error 69 57 12
Keying error 28 23 5
ITR ADJ error 8 7 1
655 486 169

Errors Module 1
Slotter error 164
Other errors 158
Letdown error 77 Module 1- Errors
180 164
Putaway error 57 160
158

Keying error 23 140

120
ITR ADJ error 7
100
77
80
60
40
Errors Module 3 20
Other errors 84 0
Slotter error 66
Putaway error 12
Keying error 5
Letdown error 1
ITR ADJ error 1
 Pareto chart

Receiving process -errors

300
242 230
250
200
150
100 78 69
50 28
8
0

ors Module 3 - Errors

64 158 90 84
80
70 66
60
77 50
57 40
30
23 20 12
7 10 5
1 1
0
 1 Slotter errors and Let down errors have to be
adressed on priority

2 Other errors have to be anaysed as it has the highest

number of recorded errors.

12
5
1 1
1
2
3
4
5
6
Continuous improvement framework

Stalk can use control charts for continuous improvement

From the pareto chart, we have identified other errors, slotter errors and letdown errros as major cause of error i
Control charts can be prepared for the slotter errors and let down errors
Deviations beyond the upper contorl limit and lower control limit should be identified and excluded and control l
Once the process is in state of statistical control, improvement measures can be implemented
On implementing improvement measures, control limits have to be recalculated using the revised mean and sta

This is a continuous process and will help in continuous improvement

control chart - p chart

pareto analysis
fish bone diagram
how how analysis