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The manufacturing plant produced millions of identical small metal parts. Even though the parts that the plant produced were identical, the facility produced them using hundreds of presses (named types 1, 2 and 3). The machine types 1, 2 and 3 produced 700, 200 and 155 parts per minute, respectively even though the actual production varied. The was an obstacle that factors that would impinge on production such as worn or “changed-out” dies, and dirty or badly serviced presses or which were substandard.

Though records were available they was an issue that they were used by none except being stashed away in the file cabinets after the reporting have been made to the concerned. It was therefore necessary to ensure that the manager had the responsibility to monitor the machines and their functions. Therefore, the report gives a guideline on steps that should be taken to improve the efficiency in the production cycle.

  • Establish core problems in the production cycle and offer recommendation on how to improve the production of identical small metallic parts
  • Develop a record keeping mechanism that will ensure and present appropriate summaries of the day’s production records.
  • Offer analytic analysis for errors in presses that either above of below the official ratings    

In type one, (with rated production rates of 700 parts per minute) an outlier was RATES/MINSWORK (no. 11) where unlike the other figures that were over 550, it was at the lowest with 457.5 while the next one that followed it was 561.1194444.

In type one press, (with rated production rates of 700 parts per minute). Therefore; the expected production rates are 665 to 735. From the presses an outlier was identified no 11 that had a value of Rates/Mins Work 457.5.

In addition the count below the production mark was 18. Similarly, the count that met the production mark was 10. The percentage below the production mark was approximately 64.3% while the percentage above that met the production mark was 35.7%. From the data we it shows that majority of the presses perform poorly. Therefore, they is need to perform maintenance and if need be replace presses that cannot be maintained.

Moreover, the data showed that where the:

  • Productions mark was met and below production time was 12.
  • Production mark was met and the production time met was 5.
  • Below the production mark and the production time was met was 6.
  • Below the production mark was met but was below the production time was 5.

From the data it reveals that majority of the presses perform unsatisfactory. Since most failed to met the threshold of meeting the Production mark and the production time

The rated of production rates was 200 parts per minute despite the fact that the rates varied. The total below the production mark was 35. The total that met the production mark was 0. The percentage that was below the production mark was 100% while the percentage above the production mark was 0%. From the data it reveals that all of the presses perform poorly. Therefore, they is need to perform maintenance and if need be replace presses that cannot be maintained.

The count that was both

  • Below production mark and below the production time was 28.
  • Met  production mark and met the production time was 0
  • Below production mark but the production time was met was 7.
  • Production mark was met but was below production time was 0.

From the data it reveals that all of the presses performed unsatisfactory. Since all failed to met the threshold of meeting the Production mark and the production time

Type three where the rated production rates were 155 parts per minute. Total below the production mark was 35 while the total that met the production mark was 18.  The percentage that was below the production mark was approximately 66% while the percentage that above and met the production mark was approximately 33.9 (rounded off to 40%).

The count that was both

  • Below the production mark and below the production time was 27.
  • Met the production mark and met the production time was 4.
  • Below the production mark but met the production time was 5.
  • Met the production mark but was below the production time was 14.

From the data it reveals that majority of the presses perform unsatisfactory. Since most failed to met the threshold of meeting the Production mark and the production time

One potential problem with data collection would be human error. Human error would arise from the human activities such as poor recordkeeping habits in manufacturing plant. Therefore poor recordkeeping would alter the values data collected.

Recommendation:

Based on my findings, I would recommend the following on how the plantcan proceed.

  • The organization needs to upgrade to computerized recordkeeping to ensure the integrity and accuracy of records
  • Ensure proper servicing and maintenance of the presses to ensure efficiency and durability of the presses
  • Train your workers so that they can handle the machines competently and improve their record keeping habits. 

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