Application of Quality Management Tools

Assignment 6

Submitted By:

Vishalakshy Babu ID: 8868334

Applied Electrical Motion and Control Management

Submitted to:
Harry Latchman

March 30th, 2023

Histogram 1: Showing Total Number of Defects on each day over a period of 3 days.

Histogram 2: Showing the frequency of each defect.

We used histogram and Pareto chart to analyze the data from table 1.

The histogram shows the distribution of each type of defect across 30 days period and frequency
of each defect, while the Pareto chart helped us to identify the most critical defects that need
immediate attention.

Based on the Pareto chart, the top four defect types, panel side cracks, dimensional error, and grip
bracket defect and panel middle cracks, account for the majority of the issues (61.98% combined).
These four types of defects make up over 61.98% of the total defects reported. Therefore, these
areas should be the focus of improvement efforts. The most frequently occurring defect type is
panel side cracks, accounting for 30% of the total defects, followed by dimensional error with
16.09%, grip bracket defect with 8.36%, and panel middle cracks with 7.53%. These defects affect
the product's quality and customer satisfaction.
 Defect Frequency of % of total Cumulative %
defect
Panel side cracks 5,431.00 30.00% 30.00%
Dimensional error 2,914.00 16.09% 46.09%
Grip bracket defect 1,514.00 8.36% 54.45%
Panel middle cracks 1,364.00 7.53% 61.98%
Panel corner cracks 791.00 4.37% 66.35%
Hex bolt thread defect 544.00 3.00% 69.36%
Pinholes In trim panel 523.00 2.89% 72.25%
Broken left bar 518.00 2.86% 75.11%
Low spring tension 467.00 2.58% 77.69%
Broken right bar 462.00 2.55% 80.24%
Peeling glaze 439.00 2.42% 82.66%
Pits in panel body 419.00 2.31% 84.98%
Dust in framework 395.00 2.18% 87.16%
Dust under glaze 384.00 2.12% 89.28%
Panel cracking under glaze 368.00 2.03% 91.31%
Hex nut defect 362.00 2.00% 93.31%
Spring nut defect 351.00 1.94% 95.25%
Spots on door handle 314.00 1.73% 96.98%
Grains in padding 305.00 1.68% 98.67%
Blind rivet defect 241.00 1.33% 100.00%

These defects can occur due to various reasons, such as improper handling during transportation,
incorrect measurements, insufficient welding or improper alignment during assembly, thermal
shock, and excessive weight on the product.

By establishing a comprehensive quality control program such as frequent quality checks at every
stage of the production process to ensure that the product meets the desired quality standards,
improving handling during transportation (appropriate packaging), addressing dimensional error,
improving grip bracket assembly( by providing additional training to the mechanical engineer),
and identifying the root cause of panel middle cracks(analyzing the production process to identify
the potential causes), the producer can improve the product's quality and reduce the frequency of
defects.

Other defects identified in the Pareto chart, such as panel corner cracks, and hex bolt thread defects
etc. should also be addressed. However, these defects account for a smaller percentage of the total
defects reported.
B). Tolerance measurement data for the "Dimensional Error" defect

Dimension error tolerance (cm)

50.00
49.90
49.80
49.70
49.60
49.50
49.40
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Days

Dimensions (cm)

Individual chart 1: Showing the variability in the “dimensional error” measurements over
30 days.

We used an individual chart to analyze the data on table 2. The above individual chart will show
variability in the “dimensional error” measurements over 30 days.

Based on the provided data, the average dimension measurement over 30 days is 50.00 cm, with a
range of measurements between 49.70 cm and 50.25 cm. The Upper Control Limit (UCL) and
Lower Control Limit (LCL) are set at 50.10 cm and 49.90 cm, respectively.

From the individual chart, we can see that most of the measurements fall within the control limits,
indicating that the process is stable. However, there are a few measurements that are outside the
control limits, dimensions measured on Day 3, Day 6, Day 9, and Day 10 were all outside of the
control limits. This suggests that there may be some variability in the manufacturing process that
needs to be addressed. We should investigate these measurements further to identify and eliminate
the root cause of the variation. This could involve examining the manufacturing process in detail
to determine whether there are any steps that could be modified, by using highly efficient modern
machines or by ensuring that all personnel involved in the production process are adequately
trained to reduce the likelihood of errors.
C). Comparison data between the frequency of “Panel Side Cracks” defect and the
Temperature of the Molding Machine.

The following table shows the number of panel side cracks in a month for the Extruded Molding
machine to produce car doors.

Number of Panel Side Cracks in a Month

450.00
400.00
350.00
300.00
250.00
200.00
150.00
100.00
50.00
-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Days

No. of panel side cracks

Line Chart: Shows the number of Panel Side cracks in a 30-day period.

The line chart above shows the trend in the number of panel side cracks over time. It can be
observed that the number of failures tends to decrease in a month. However, it can be highlighted
that in the first 5 days of the month, the number of panel side cracks is very high with respect to
the rest of the month, followed by a sharp decrease on day 6, where they decrease by almost 100
failures less and after the sixth day, The number of panel side cracks remains relatively low for the
rest of the days of the month with some fluctuations in the middle (i.e. it remains stable between
100 and 170 failures per day.)

These high failures in the first 5 days of the month can be attributed to the machine start-up
configurations that are performed at the beginning of production. It may be beneficial to conduct
more frequent inspections during the first few days of production to identify any potential issues
with the panels.
Also, the cause of this failure can be attributed to several reasons, among them may be an
inadequate temperature in the plastic extrusion machine for the manufacturing of the door panel.
In the next table, we can see the Temperature used in the machine for a month in Guelph Auto
Manufacturers.

Temperature used in the Extruded Molding Machine

42.00
Temperature (Deg C)

40.00

38.00

36.00

34.00

32.00

30.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Days

Temperature (Deg C)

Line Chart: Variations of Temperature in a Month

The line chart below shows the trend in temperature over time, it can be observed that the
temperature remains relatively stable throughout the 30-day period, with some fluctuations in the
middle, and the temperature setting used in the machine is on average between 32 and 38 degrees
during the month with some peaks of temperature reaching 42 degrees Celsius. However, in the
first 5 days of the month, we see that the temperatures used are within the values used when the
faults in the panel remain stable (from day 6 to 30).

With this analysis, it is difficult to attribute the cause of the car door panel failures solely to the
temperature setting of the plastic melting machine. To find the root cause of this failure, more
variables must be taken into consideration such as the purity of the plastic pellets, the humidity
level of the compressed air used to blow the plastic sleeves, the integrity of the mold surface, the
cooling temperature of the panel as it exits the machine, among other reasons.
 No. of panel side cracks vs Temperature
500.00
450.00
400.00
No. of Panel Side Cracks

350.00
300.00
250.00
200.00
150.00
100.00
50.00
-
30.00 32.00 34.00 36.00 38.00 40.00 42.00 44.00
Temperature (Degree Celsius)

Scatter Diagram: Number of Panel side cracks vs Temperature used in the machine.

The scatter diagram shows the correlation between the number of panel side cracks and
temperature. In the Scatter Diagram, there is a low correlation between the temperature and the
number of panel side cracks. However, a trend line can be drawn with a slightly decreasing
tendency (there is a slight negative correlation between the two variables), which can lead to the
idea that with a greater temperature, the number of failures can decrease. However, this correlation
is not particularly strong, indicating that there may be other factors that affect the occurrence of
panel side cracks.

It should be considered whether the temperature used is the recommended working temperature
for the plastic material used. If PET is being used, the temperature should be between 150-160
degrees Celsius.

Polypropylene is used the most frequently of any plastic in automotive manufacturing. Being a
thermoplastic polymer, it can easily be formed into almost any shape. It has excellent chemical
and heat resistance and is generally resistant to impact. (Car Plastic – 4 varieties used in the
automotive industry, 2023).
The working temperature of this plastic is 82 degrees Celsius which is more that the temperature
used by Guelph Auto Manufacturers. This can be the reason why the panel side cracks is the
largest single cause of failure. The scatter diagram and line chart suggest that temperature may
have some effect on the occurrence of panel side cracks, so it may be beneficial to conduct
experiments to determine the optimal temperature range for reducing this defect

Conclusion:

➢ After analyzing all the provided data, the following findings were observed:
➢ The most frequent defect is "Panel side cracks" with 30% of the total defects, followed by
dimensional error with 16.09%, grip bracket defect with 8.36%, and panel middle cracks
with 7.53%. Therefore, efforts should be focused on reducing these two types of defects
first.
➢ All the measurements for the "Dimensional Error" defect are within the control limits, and
any deviations from the desired dimension are likely due to random variation, indicating
that the process is stable and within acceptable limits of variation.
➢ The process for the "Dimensional Error" defect is in control, and any deviations from the
desired dimension are likely due to random variation.
➢ The scatter diagram shows a low correlation between the temperature and the number of
panel side cracks. There is a slight negative correlation between the two variables,
indicating that with a greater temperature, the number of panel side cracks may decrease,
but this correlation is not particularly strong. Indicating other factors may be affecting the
occurrence of panel side cracks.
➢ Based on the above findings, the following recommendations are suggested for improving
the production process:
➢ Implement statistical process control techniques to monitor the production process and
identify the root causes of the major defects.
➢ Improve operator training and introduce quality checkpoints in the production process to
prevent defects from occurring in the first place.
➢ Continue to monitor the "Dimensional Error" defect using the individual chart and adjust
the process as necessary.
➢ Conduct further analysis to identify other factors that may be affecting the occurrence of
"Panel side cracks" and develop strategies to address those factors.
➢ Regularly review and analyze production data to identify trends and patterns and make
informed decisions to improve the production process.
 Reference

• Car plastic - 4 varieties used in the automotive industry. Car Plastic - 4 Varieties Used In
The Automotive Industry. (n.d.). Retrieved March 29, 2023, from
https://www.acplasticsinc.com/informationcenter/r/plastic-used-in-
cars#:~:text=Polypropylene%20is%20used%20the%20most,is%20generally%20resistant
%20to%20impact.