STATISTICAL

DESCRIPTION OF THE PROBLEM

The automotive branch that has a lot of defects in the production process, and is getting worse with the
the time. All the production stages that present problems are the main causes of the defects in the final
that is why the goal is to reduce those defects through implementation of improvements, not only i
technical processes, but also in organizational processes. The need to still in the long run in competition
that companies try to find solutions to the problems, through the investment in statistics tools and inn
methods that helps to reduce the amount of defects in the production process and guarantee a good pr
control. For the specific case, statistical tools are used such as the Pareto chart and the cause and effect
that help to perform a quantitative and qualitative analysis.

Pareto Diag
Name Cost % Acumulated
Exceeding the dimension tolerance 7280 26% 7280
Improper hardness 6840 24% 14120
Cracks of the forging 6000 21% 20120
Damage to the surface of the forging 4640 16% 24760
Fractures 2000 7% 26760
Skews 720 3% 27480
Dents 650 2% 28130
Total 28130 100%

CONCLUSIONS AND RECO

Pareto's diagram made it easier for us to study what the company's failures were, as well as to establis
manufacturing process. This is to ensure that parts for the automotive industry successfully meet marke
right.According to the pareto diagram we can analyze that the vital few explain most of the problem, s
 Pareto's diagram made it easier for us to study what the company's failures were, as well as to establis
manufacturing process. This is to ensure that parts for the automotive industry successfully meet marke
right.According to the pareto diagram we can analyze that the vital few explain most of the problem, s
consider that the vital few do not explain 80% so we took 88% of these defects, These defects are: Exce
surface of the forg
Some recommendations so that the company can stay in the market based on the pareto diagram is th
the part has or may present a crack over time. We can also recommend that the company take measure
one of the vital few areas that significantly affect the manufacturing process. In addition, we recomme
these defects; the few trivial ones that may be ca

Cause-Effect D

Man power
Poor distribution of
work

Leisure time
Obsolete eq
Lack of training
Low salaries
Lack of motivation B
Non-existence
of formation
program

Bad tansportation, Excessive work hours

storing and
packaging Bad quality
control syst
Poor production
Low quality of planning
raw material Low Unk
investment of
Lack of comunication in I+D
Non- between areas
qualified Materials Methods
suppliers
 qualified Materials Methods
suppliers

CONCLUSIONS AND RECO

For the elaboration of the Cause-Effect diagram, the most expensive defect was chosen to per

As can be seen in the Cause-Effect diagram, there are different factors that affect the tolerance of the d
order to facilitate the analysis of the main factors that c

Man power: This area is the most important of the company because it involves the most important re
training were the main causes of failures in the human resour
To begin with, it can be inferred that leisure time is presented due to a poor distribution of work, wh
percentage of use of human capital and the optimum leisure time that should be given and not cause
hand, lack of motivation is a big problem in companies in general. This cause may be due to differe
remuneration, when it does not satisfy them, it becomes inconvenient since they do not find it attractiv
the human resource. When the worker is not trained correctly
For these reasons, it is recommended to implement surveys to workers about their level of satisfacti
excellent work development so that the human resource is not a lim
Machines: The machines are part of the company's assets, and these represent an important role in any
be treated. The causes of causing problems can be: lack of maintenance, obsolete equipmen
For this case, the causes are mostly consequences of the low budget of the company since it is not in e
achieve a good distribution of the machines in order that the locatio
For this reason, it is recommended to carry out a financial analysis where the company's ability to ma
optimal location of the

Materials: The material for the creation of any product represents an entrance to the process that tur
product will have defects. For this reason, the bad transportation, storage and packaging of the raw mat
raw material in most companies is provided by a supplier, you should know the risk that runs with
For this case, it is advisable to have a control over the material, which allows the raw material to be ta
company carry out a vertical integration where it is responsible for the managem

Measurements: In the automotive market, the measures with extremely important. The problem of
instruments are not in good condition, they are not calibrated or simply by huma
For this reason, the constant calibration of the instruments used for the inspection is recommended, in
once they meet the useful life they can have large margins of error. It is also recommended the use of
may occur in the production pro
Methods: As we can see one of the aspects that most affects the problem described in the diagram are
control system causes the productivity of the process decrease substantially. One of the changes to
resources, safer work and inc
We can identify that one of the causes that can have the most impact on the non-compliance with the t
make a plan to improve the production control process, in which inspection stations are contemplated
Similarly, it is suggested to implement planning strategies that bring together all areas to develop a prod
and stay in the market. Also, we can suggest the implementation of working hours that allow the opera
affect his physical and m
 resources, safer work and inc
We can identify that one of the causes that can have the most impact on the non-compliance with the t
make a plan to improve the production control process, in which inspection stations are contemplated
Similarly, it is suggested to implement planning strategies that bring together all areas to develop a prod
and stay in the market. Also, we can suggest the implementation of working hours that allow the opera
affect his physical and m

FINAL CONCLU
After working in this laboratory, we conclude that statistical and graphic tools are very useful alternativ
status of an organization or a process. The most important thing of these analyzes is to find the main c
After analyzing the cause and effect, and pareto diagram, we see as the set of factors are them man po
impact on the quality of the final product. All defects identified in the diagram pareto are the result of
the final product leaves. We can see that defects found generate high costs for the company, howeve
diagram to prioritize the defects that are imp
After analyzing the pareto diagram, we recommend that inspections should made by a trained professi
We can also recommend that the company take measures in the areas of transportation, storage and p
affect the manufacturing process. In addition, recommended to implement surveys to workers about th
that guarantee excellent work development. The company should carry out a financial analysis wh
distribution study to achieve the optimal location of the machinery and guarantee the constant calibrati
control over the material, which allows the raw material to be taken without defects at the entrance of
where it is responsible for the management or production of the raw material and not depend on a s
develop a production plan according to the objectives of the company
ATISTICAL TOOLS

getting worse with the pass of

the defects in the final product,
provements, not only in the
ong run in competition causes
statistics tools and innovation
d guarantee a good production
d the cause and effect diagram
lysis.

Pareto Diagram
% Acumulated
26% Pareto Diagram
50% 100%
72%
25000 90%
88%
80%
95%
98% 20000 70%
100% 60%
15000
50%

40%
10000
30%

5000 20%

10%

0 0%
1 2 3 4 5 6 7
Cost % Acumul ated

SIONS AND RECOMMENDATIONS

e, as well as to establish an order of priorities so that the company could manage, make decisions and organize its
ccessfully meet market objectives. In the graph we place the few that are vital to the left and the many trivial to the
most of the problem, studying the case we could conclude that the percentage of vital few is greater than 80%, we
 Cause-Effect Diagram

Machines
Low budget

Lack of maintenance

Obsolete equipment
Inadequated machine
ing distribution

Bad monitoring
istence system Unknowledge of
mation distributions
gram strategies Exceeding
the
ork hours dimension
Human errors tolerance
Bad quality
control system
on
ng Non calibrated
tools
Low Unknowledge
investment of statistics
in I+D tools

hods Measurement
hods Measurement

SIONS AND RECOMMENDATIONS

fect was chosen to perform an analysis of the causes of this problem, exceeding the dimension tolerance.

t the tolerance of the dimension in the automotive industry. We decided to classify these causes into five groups in
the main factors that cause the excess tolerance of the dimension:

the most important resource: the human resource. It was deduced that leisure time, lack of motivation and lack of
s in the human resource that in turn causes the main problem of concern.
stribution of work, which shows a bad planning and programming, since at the time of distributing the work the
e given and not cause excessive leisure time that at the end of the day can result in low productivity. On the other
may be due to different factors, such as low wages, given that a large percentage of people work for economic
do not find it attractive to do the work. Also, the lack of training, represents a vital cause to any problem present in
is not trained correctly the probability of having system failures is greater.
their level of satisfaction with their work and, in short, the implementation of training programs that guarantee
an resource is not a limiting resource or a cause of excess dimension tolerance.
n important role in any production process. This resource in poor condition can be the vital cause of the problem to
ce, obsolete equipment, inadequate distribution of machinery, poor monitoring systems, among others.
pany since it is not in economic conditions to keep the machinery in good condition and cannot hire quality staff to
n order that the location of these represent an advantage to the production flow.
ompany's ability to maintain the machines is evidenced and, in addition, a plant distribution study to achieve the
optimal location of the machinery.

to the process that turns it into an output. Thus, if from the entrance the material has defects, the exit, that is, the
ckaging of the raw material can cause permanent defects in the future product. In sum, taking into account that the
the risk that runs with said supplier, since having unskilled suppliers can mean having low quality raw material.
e raw material to be taken without defects at the entrance of the process. It could also be recommended that the
nsible for the management or production of the raw material and not depend on a supplier.

ortant. The problem of exceeding the tolerance dimension is based on the measurements. When the measuring
ted or simply by human error the measurements are taken badly, great losses can be caused.
n is recommended, in addition, the renewal of the measurement tools when they accomplish their useful life, since
ommended the use of tools that are not subject to the operator's total handling since the measurement errors that
r in the production process can be reduced.
bed in the diagram are the methods. Having poor production planning, excessive working hours and a poor quality
One of the changes to be promoted is the improvement of these work methods that seek to improve the use of
ces, safer work and increased efficiency.
-compliance with the tolerances of the process may be the lack of a quality control system, so it is recommended to
ons are contemplated at each stage of the process to prevent errors within the production from being propagated.
reas to develop a production plan according to the objectives of the company and that allows them to be profitable
urs that allow the operator to have a short leisure time that allows him take a rest from long hours of work that can
ffect his physical and mental health.
 FINAL CONCLUSIONS
e very useful alternatives to analyze any process. The diagrams are easy to build, but they can tell us a lot about the
es is to find the main causes of any problem and then concentrate the improvement strategies to the critical areas.
ctors are them man power, machines, raw material, measurements and production methods generate a significant
areto are the result of errors that can occur in any part of the process from when the raw material is received until
the company, however, it is very difficult to reduce them all at the same time, it is here that we rely on the Pareto
he defects that are important to minimize the costs given.
e by a trained professional who is able to notice when the surface of the part has or may present a crack over time.
ortation, storage and packaging of the material, as these also represent one of the vital few areas that significantly
ys to workers about their level of satisfaction with their work and, in short, the implementation of training programs
a financial analysis where the company's ability to maintain the machines is evidenced and, in addition, a plant
the constant calibration of tools that people used in the production process. With materials it is advisable to have a
ects at the entrance of the process. It could also be recommended that the company carry out a vertical integration
and not depend on a supplier. Finally, we suggest to implement planning strategies that bring together all areas to
ctives of the company and that allows them to be profitable and stay in the market.
 100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%
7

ons and organize its

the many trivial to the
reater than 80%, we
 n tolerance.

es into five groups in

motivation and lack of

uting the work the

ctivity. On the other
ork for economic
ny problem present in

ms that guarantee

use of the problem to

ng others.
ot hire quality staff to

tudy to achieve the

, the exit, that is, the

into account that the
ity raw material.
ommended that the

hen the measuring

their useful life, since

surement errors that

urs and a poor quality

mprove the use of

it is recommended to
m being propagated.
them to be profitable
ours of work that can
tell us a lot about the
to the critical areas.
generate a significant
erial is received until
e rely on the Pareto

ent a crack over time.

eas that significantly
n of training programs
addition, a plant
t is advisable to have a
a vertical integration
ogether all areas to