Route 44 Soft Drink AN ANALYSIS ON PROCESS CAPABILITY, AND CONTROLS

We are excited!!! Hello Route 44 drive in! It seems since our last visit, we have seen some improvements in your process. Most importantly, our failure mode pareto we placed into the PLC of your Soda machine seems to be working and has given us some insight into what our next steps are to drastically improving your fill process and leading the way to more satisfied customers! We have made some calculations for you to observe, and disclosed the Pareto charts for you to examine what the root causes of your fill variation is.

Establishing control limits and CPK SampleDrink 1 Drink 2 Drink 3 Drink 4 Drink 5 X BARR X DOUBLER BAR R BAR UCL 0.00 R BAR LCL 49.31X BAR UCL 40.75X BAR LCL SIGMA 0.45CP 0.45 CPK Here is the data from the samples that you ran while visiting your restaurant’s. We made some basic calculations to extrapolate the LCL, and UCL for your X bar (data distribution of fill weights.) We then used that data to come up with our standard deviation (or 1 sigma) to help us calculate the CP of your process. Cp= UCL-LCL/6 Sigma. The performance of your process is quite low. The capability is only a 2 sigma process Based on this data, we expect to see roughly 235,000 defects (outside of your UCL, and LCL) per 1,000,000 soft drinks

Visual demonstrations of the data Using Minitab, we have ran a capability analysis (on the left), and a control chart (on the right) of your process from the data we compiled. The CP and CPK are slightly different from our manual calculations, as the calculation for 1 sigma is done slightly differently with minitab.

Performance to Eng. Specs 15.58R BAR UCL 0.00 R BAR LCL 46.00X BAR UCL 42.00X BAR LCL SIGMA 0.21CP 0.10 CPK 0.10 CPK Again, we have taken the manual calculation for CP and CPK using your engineering specifications. The manual calculations are shown here. I have attached the graphical minitab analysis as well for your review. Based on the new specs, it looks like we have a lot of work do to! We expect this process to produce 596,000 defects per 1 million attempts! This figure represents a capability of 1.3 sigma. Over ½ of our customers will be getting more, or less soda than we are advertising our sales to be.

Failure Mode Pareto Below is the Pareto charts from the software we have installed to your PLC! I think you will find it enlightening!

Lets establish some goals and targets! I propose we dedicate our efforts initially to seeing a 50% reduction of Fill servo faults. It seems that we are having problems with the encoder sensors that we installed, and our engineers have found a sensor that should be much improved! Assuming we are successful, below is what your process performance should look like! X DOUBLER BAR R BAR UCL 0.00 R BAR LCL 46.00X BAR UCL 42.00X BAR LCL SIGMA 0.28CP 0.21 CPK 0.34 CPK 194,444PPM As you can see, by showing a 50% reduction in one defect category, we have effectively reduced our PPM rating by over 50%. We have also increased CPK from.10 to.21!!!