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Trinadh Mamandur 05/01/2014

Bayfield Mud Report

As a consultant of Bayfield Mud, below is my report on the case analysis.

Problem Statement
It was highlighted in the case that it was suspected that only occasional reminders were made to
double check the bag weight-feeder. If there is significant deviation from 50 pounds, corrective
adjustments are made to the weight-release mechanism. To verify this expectation, the quality
control staff randomly samples and weighed each hour.

Objective
To identify and document any deviations from the correct weighted total of the bag weight-
feeder exceeding 50 pounds.


Excel OM software has been used to analyze this case.

Control Charts

Day Shift

Day 1













47
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Sample
x-bar chart
Data
LCL
CL
UCL
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Trinadh Mamandur 05/01/2014
Day 2


Day3


Evening Shift

Evening 1




0
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R
a
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Sample
range chart
Range Data
LCL
CL
UCL
46
47
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50
51
52
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
0
2
4
6
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10
1 2 3 4 5 6 7 8
R
a
n
g
e
Sample
range chart
Range Data
LCL
CL
UCL
45
46
47
48
49
50
51
52
53
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
0
2
4
6
8
10
1 2 3 4 5 6 7 8
R
a
n
g
e
Sample
range chart
Range Data
LCL
CL
UCL
46
47
48
49
50
51
52
53
54
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
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Trinadh Mamandur 05/01/2014

Evening 2


Evening 3


Night Shifts

Night 1



0
2
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12
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R
a
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e
Sample
range chart
Range Data
LCL
CL
UCL
42
44
46
48
50
52
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
0
2
4
6
8
1 2 3 4 5 6 7 8
R
a
n
g
e
Sample
range chart
Range Data
LCL
CL
UCL
44
45
46
47
48
49
50
51
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
0
2
4
6
8
10
1 2 3 4 5 6 7 8
R
a
n
g
e
Sample
range chart
Range Data
LCL
CL
UCL
44
45
46
47
48
49
50
51
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
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Trinadh Mamandur 05/01/2014
Night2


Night3




Q 1. What is your analysis of bag weight problem?
Analysis
The results from the statistics show that there was a statistical control on the day shift for the first
days, that is, the weight of the bags fell within the operational limits. The assumption is that
because the problem exists across all the shifts then there may be a problem with the machine,
possibly a malfunction or gradual deterioration of quality due to machine wear. This is so
because statistics has shown that the machine has been performing to standards before the
problem arise. Because the machine operates acceptable within the control limit for shift 1 and
shift 2. For all shifts statistics show that production was indeed out of control. In concluding,
there was a small change in the average of the bag weights. The average weights of the bag fell
within the average limit except for one shift, this 14shows that the machine is operating at a
consistent level but not within the acceptable control limits.



0
1
2
3
4
5
6
7
1 2 3 4 5 6 7 8
R
a
n
g
e
Sample
range chart
Range Data
LCL
CL
UCL
45
46
47
48
49
50
51
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
0
1
2
3
4
5
6
1 2 3 4 5 6 7 8
R
a
n
g
e
Sample
range chart
Range Data
LCL
CL
UCL
45
46
47
48
49
50
51
52
1 2 3 4 5 6 7 8
M
e
a
n
Sample
x-bar chart
Data
LCL
CL
UCL
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Trinadh Mamandur 05/01/2014

Q 2. What procedures would you recommend to maintain proper quality control?

Recommended Procedures for Proper Quality Control

1. Employee empowerment is one of the key aspects of dealing with this problem, this has to be
done through continuous training and development to educate them on how to follow guidelines
and procedures set by the company, and how to report them.

2. Setting up policies and procedures to monitor and report machine problems has to be in place
for machine operators to report machine problems and other inefficiency. This will be a part of
the companys Total Quality Management plan.

3. Continuous improvement of the machines should be done on a regular basis, such as bi-
monthly or annually, as this machine is a key asset to the companys revenue model.

4. The company can put in place automated testing devices to inspect every single unit that is
produced. In that case, machine operators will be informed of any defects in the functional
ability of the machines and detecting even small shifts in the production.

5. Periodic auditing by a quality control personnel should be done and documentation completed,
so as to be able to track repeat problems. The documentary evidence should be submitted to
management and the manufacturers of the machine, this can help to reduce cost where the
product still be under warranty or may be awarded a refund or exchange. The audit reports must
be periodically reviewed and corrective actions be taken to resolve the problem.

6. An immediate action that the company can take to fix this problem is in the form of Robust
Quality, that is, they dont have to fix the machine right away because it is needed for the
companys revenue making, what they need to do is just control the effects of the machine, until
the time is approximate to fix or replace it.


Thanks,

Trinadh Mamandur