1. Production Analysis Tom Schambow Katie Cusack Stephen Willoughby

2. Situation This company realized the number of defective units being produced out of their product lines was significantly high. The company decided to analyze information involving every batch. The following information was submitted for review. Batch Product Machine Employee Batch Size Number Defective

3. Employee Analysis After analyzing each employee and their rate of defective products produced by themselves, we found that no single employee had a significantly higher defective rate than the other employees. This led to an analysis of the machines and batch sizes.

4. Batch Analysis When analyzing each batch, it became apparent products had a higher rate of defectiveness when the batch size was 500 than any other batch size. The percentage of defective products in a batch size of 500 was 35.6% compared to the batch size of 10,000 with a defective rate of 2.4%. This led to the conclusion of products in a batch size of 500 was the problem.

5. Machine Analysis After analyzing the batch size, we further looked to see if any single machine was performing worse than the other machines. We found that machines 6 and 8 failed to perform effectively in batch sizes of 500. They had a higher percentage of defectiveness compared to the other machines.

6. How to fix these problems? The solution to these problems is simple. The amount of smaller batch sizes must be reduced, forcing larger batch sizes to be produced. We also recommend performing diagnostic tests and maintenance work on machines 6 and 8. To view justification of the analysis please view Excel worksheets “Batch Size Pivot Table” and “Machine 6 and Machine 8 Filters” in the related Excel document.