Carton Manufacturing Defects

Total
Line 1 Line 2 Line 3 Defects
Bent/Damaged flaps 37 22 24 83
Carton will not open 29 18 29 76
Damaged Pallet 3 3
Fisheye 9 9
Folded flaps 16 6 83 105
Ink smears/streaks 5 19 24
Mislabeled 3 3
Missing color 8 8
Off color 14 5 12 31
Oil spots 14 14
Poor ink adhesion 7 8 18 33
Undercount 2 2
Instructions
1. Select cells A2:A14,E2:E14 using your mouse (CTRL to select second column)
2. Click on Pareto Chart
3. Review the Pareto chart - Folded Flaps is the most common problem
4. Come back to this sheet and select A2:E14 and run the Pareto Chart
5. Open your own data and run a Pareto Chart

Pareto Chart
Practice
and
Application
 Manufacturing

Carton Manufacturing Defects (Quality Digest Dec 2006) Lost Time Analysis (LTA)
Total
Line 1 Line 2 Line 3
Defects
Folded flaps 16 6 83 105 Generator Failure
Bent/Damaged flaps 37 22 24 83 Conveyor Failure
Carton will not open 29 18 29 76 Training
Poor ink adhesion 7 8 18 33 Safety
Off color 14 5 12 31 Flooding
Ink smears/streaks 5 19 24 Pump Failure
Oil spots 14 14
Fisheye 9 9 Causes of Lost Time
Missing color 8 8 Work Instructions
Mislabeled 3 3 Bill of Materials
Damaged Pallet 3 3 Work Orders
Undercount 2 2 Out of Stock
Wrong parts or material
Circuit Board Defects Lack of tools
Bad 8 Bad assembly
Bridge 1

Damage 6
Excess 3 Location 1
Extra 1 Location 2
Insult 9 Location 3
Lifted Lead 5 Location 4
Missing 6 Location 5
Open 2 Location 6
Orient 2 Location 7
Poor Wetting 1 Location 8
Solder ball 2 Location 9
TH Void 16

Install Replace Adjust Lube Total

Door 2 5 1 0 8
Motor 2 1 11 6 20
Track 1 0 6 4 11
Vinyl 11 1 0 0 12
T-Lock 9 0 1 0 10
Total 25 7 19 10 61

Page 3
 Manufacturing

Scrap % of
Description Scrapped Qty Ship Qty
Shipped
Lost Time
(Minutes) Support 169 2000 8.45%
346 Poppet 78 2000 3.90%
71 Core 135 3500 3.86%
34 Stainless Body 64 2486 2.57%
26 Solid Top Axle 4 197 2.03%
20 Armature 93 5000 1.86%
9 Aluminum Washer 76 4970 1.53%
Flange 34 2300 1.48%
Incidences Safety Plug 56 4000 1.40%
45 Neck 1 79 1.27%
40 Stainless Washer 11 1037 1.06%
30 Terminal Cap #8 10 1065 0.94%
7 Barrel 18 2148 0.84%
7 Terminal Cap #10 12 1955 0.61%
7 G30 Front Wearplate 3 500 0.60%
7 Low Profile Housing 1 215 0.47%
Solid Body 1 303 0.33%
Service
Lost
Order
Time
Rejects Stainless Washer 2 1060 0.19%
7564 630 G20 Wearplate 3 5046 0.06%
13618 106 Stainless Washer 1 2070 0.05%
2121 37
5121 293 Defectives Guide to Quality Control (Ishikawa)
6341 288 Caulking 198
7116 710 Fitting 25
5212 516 Connecting 102
16447 654 Torque 18
6530 504 Gapping 72

Page 4
 Manufacturing

Tank Defects

Incorrect Dimensions 36
Parts damaged 34
Machining 29
Insufficient masking 17
Parts rusted 13
Adhesive failure 6
Film on parts 5
Salt spray failure 4
Out of order 4
unfinished fairing 3
Wrong part issued 3
Weld misaligned 2
Paint out of spec 2
Delaminated composit 2
Voides in casting 2
Paint damaged 1
Primer damaged 1

improper procedure 1
powdery alodine 1

ntrol (Ishikawa)

Page 5
 Defective Number of
Guide to Quality Control (Ishikawa) pg 42
Items Defectives
Caulking 198
Fitting 25
Connecting 103
Torque 18
Gapping 72
Restaurant Complaints Number Lean Six Sigma
Cold Food 105 Donna Summers
Flimsy Utensils 20 pg 97
Food tastes bad 10
Salad Not Fresh 94
Poor Service 15
Food Greasy 9
Lack of Courtesy 5
Lack of Cleanliness 25

Bank Call Center Calls

Credit Card Payment Questions 245
Transfer Call 145
Balance Questions 377
Payment Receipt Questions 57
Finance Charge Questions 30
Other 341
 Healthcare

Medication
Claim Denied
Errors
(No Appeal)
Baseline
Timely Filing $ 7,849,569 Wrong Technique 41
Medical Necessity $ 2,516,508 Wrong Time 33
No Authorization $ 1,295,032 Wrong Dose 5
Partial Authorization $ 750,766 Wrong Route 5
Invalid Auth for Patient Status $ 336,270 Drug not available 3
Wrong Form 3
Surgical Retained Foreign Objects # RFOs
Extra Dose 1
Sponges 23 Unauthoried Drug 0
Instrument 1 Omission 0
Needles 3
Miscellaneous 7

Type of
Order Entry Wrong Site
Pharmacy
Errors or Patient
Surgery
Order not received 51 Orthopedic Surgery 52
Wrong Frequency of Dose 47 General Surgery 25
Duplicate order entry 20 Neurosurgery 18
Wrong Dose 20 Urologic Surgery 13

Omission Drug 19 Other 18

Order not Discontinued 13
Wrong Site
or Patient
Additional Instructions 13 Surgery
Wrong Drug 11 Wrong Body Part or Site 96
Wrong Patient 3 Wrong Patient Surgery 17
Wrong Route (IV vs Intramuscular) 2 Wrong Procedure 13

Missed Start Wrong Site

Times in Cath or Patient
Lab Surgery
Room Not Read 43 wrong patient 34
Doctor Not Ready 88 wrong procedure 39
Prior Procedure Too Long 47 wrong side 298
Prior Case Add On 26 wrong part (60) 60
Prior Case Too Early 84
Case Start Early 19

NJ Impact of
Adverse Adverse Event Patient falls in New Jersey Ho
Events
Additional laboratory testing 283 NJ 2007 Falls 2005

Page 8
 Healthcare

Additional patient monitoring 270 Patient Room 103

Physical disability or mental impairment 185 Hallway 6
Increased length of stay 183 Emergency Department 8
Major surgery 121 Radiology 1
Transfer to higher level of care 91 ICU/CCU/TCU 1
Death 72 Telemetry Unit 1
Minor surgery 53 Cardiac Catheterization La 0
Other additional testing 38 Rehabilitation Areas 1
System/process delay 38 Other 3
To be determined 35
Hospital admission 23
Loss of bodily function 13
Other 13
Loss of sensory function 10
Loss of organ 4

Page 9
 Healthcare

Medication Medication Lab

Type of
Errors Errors Order Quantity
test
6 months 18 months Errors
25 5 SSN 226 Chemistry 22063
13 16 Name 71 Hematolog 5532
1 2 DOB 58 Urine 2292
1 0 Test 44 Serology 1043
5 4 Doctor 39 Bacteriolog 673
0 0 Other 16

3 2
2 1
2 0

Missing
Billing
Coding
and Info
Joint Commission Dec 5, 2001 Pharmacy 76
Diagnosis 12
Treatment charge 11
Account type 6

Venipuncture 5
Other 6

Joint Commission Dec 5, 2001

Drug Use Volumne and costs

Total
Units
Drug Cost/unit Cost
Used
($000)
A 180 361 65
B 250 160 40
C 950 347 330
D 90 389 35
E 75 267 20
F 560 89 50
G 1350 11 15

ent falls in New Jersey Hospitals

H 650 169 110
Falls 2006 Falls 2007 I 220 114 25

Page 10
 Healthcare

132 152 J 15 1333 20

12 14 K 56 1518 85
12 12 L 150 1367 205
3 4
3 4
0 4
2 2
2 2
2 2

Page 11
 Healthcare

Medication New Effects of Effects of

Adverse Events Other
management Medications surgery tests
infection 0 0 38 6 7
Injury 0 3 84 6 3
Mycardial infarction 0 0 9 2 7
Deep vein thrombosis 1 0 9 1 1
Fall 1 0 3 1 11
Pressure Sores 0 0 6 0 7

Rash 0 71 3 5 13
Breathing Problems 1 7 18 0 8
Confusion 1 27 3 0 0
Dizziness 1 40 0 0 1
Drop in Blood Pressure 3 25 23 3 9
Nausea 2 70 0 5 0

Pain 9 0 9 7 3
Other responses 37 91 0 6 1
Other events 0 3 84 30 20
total 56 337 289 72 91

Patient Reported
Errors

Medical Error 26

Pharmacy 12
Clinician 14
Nonmedical Error 22
Insurance or billing 7
Scheduling 6

Wrong Information 6
Prescription Delay 2
Test results delay 1
Behaviour/Communication 49
Waiting time 18
Clinician disrespect 11
Staff disrespect 8
Felt rushed 4

Technician care 2
Other 6

Page 12
 Healthcare

Misunderstanding 112
Medical Care 71
Medication side effects 15
Clinician unhelpful 11
Scheduling 7
Ordering 4
Insurance Coverage 3
Missing documentation 1

Page 13
 Healthcare

Prescribing
Errors
Allergy Related 55
Ambiguous Order 5
Delayed Treatment 3
Duplicate Additive (TPN) 18
Dupliate Order 13
Duplicate Therapy 12

Illegible 16
Incomplete (TPN and chemotherapy) 174
Incomplete other 7
Ion implance (TPN) 25
Overfill (TPN) 53
Rate/volume (TPN) 35

Unnecessary dose or medication 7

Unordered medication 29
unstable 60
Wrong calculation 11
Wrong concentration 17

Wrong Dose 355

Wrong dose of additive 30

Wrong drug 28
Wrong drug Additive 3
Wrong duration of therapy 9
Wrong dosage form 59
Wrong Frequency 81

Wrong Patient 10
Wrong rate ofinfusion 9
Wrong Route of adminsitration 22
Wrong Schedule 40
Wrong volume 4
Wrong weight 6

Page 14
 Defect <-- Click the heading and then select, "Pareto Chart"
Bent/Damaged flaps
Carton will not open
Folded flaps
Folded flaps
Off color
Bent/Damaged flaps
Carton will not open
Bent/Damaged flaps
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Ink smears/streaks
Folded flaps
Carton will not open
Carton will not open
Poor ink adhesion
Carton will not open
Off color
Bent/Damaged flaps
Carton will not open
Carton will not open
Folded flaps
Poor ink adhesion
Poor ink adhesion
Ink smears/streaks
Folded flaps
Poor ink adhesion
Carton will not open
Folded flaps
Bent/Damaged flaps
Carton will not open
Folded flaps
Poor ink adhesion
Off color
Carton will not open
Off color
Carton will not open
Folded flaps
Bent/Damaged flaps
Carton will not open
Bent/Damaged flaps
Carton will not open
Poor ink adhesion
Folded flaps
Carton will not open
Poor ink adhesion
Poor ink adhesion
Bent/Damaged flaps
Oil spots
Folded flaps
Folded flaps
Folded flaps
Carton will not open
Folded flaps
Off color
Carton will not open
Bent/Damaged flaps
Bent/Damaged flaps
Carton will not open
Folded flaps
Off color
Carton will not open
Carton will not open
Bent/Damaged flaps
Off color
Poor ink adhesion
Bent/Damaged flaps
Poor ink adhesion
Folded flaps
Bent/Damaged flaps
Folded flaps
Fisheye
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Folded flaps
Carton will not open
Off color
Poor ink adhesion
Fisheye
Folded flaps
Poor ink adhesion
Carton will not open
Carton will not open
Folded flaps
Bent/Damaged flaps
Carton will not open
Missing color
Bent/Damaged flaps
Folded flaps
Poor ink adhesion
Bent/Damaged flaps
Carton will not open
Carton will not open
Off color
Bent/Damaged flaps
Folded flaps
Fisheye
Folded flaps
Folded flaps
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Ink smears/streaks
Folded flaps
Folded flaps
Folded flaps
Poor ink adhesion
Folded flaps
Folded flaps
Folded flaps
Bent/Damaged flaps
Folded flaps
Off color
Folded flaps
Bent/Damaged flaps
Poor ink adhesion
Folded flaps
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Oil spots
Bent/Damaged flaps
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Oil spots
Folded flaps
Folded flaps
Carton will not open
Bent/Damaged flaps
Bent/Damaged flaps
Oil spots
Bent/Damaged flaps
Bent/Damaged flaps
Ink smears/streaks
Carton will not open
Folded flaps
Carton will not open
Poor ink adhesion
Folded flaps
Ink smears/streaks
Folded flaps
Carton will not open
Fisheye
Ink smears/streaks
Off color
Poor ink adhesion
Poor ink adhesion
Bent/Damaged flaps
Carton will not open
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Poor ink adhesion
Carton will not open
Carton will not open
Ink smears/streaks
Folded flaps
Ink smears/streaks
Carton will not open
Ink smears/streaks
Carton will not open
Folded flaps
Poor ink adhesion
Folded flaps
Carton will not open
Carton will not open
Off color
Poor ink adhesion
Poor ink adhesion
Mislabeled
Off color
Fisheye
Ink smears/streaks
Folded flaps
Folded flaps
Carton will not open
Oil spots
Ink smears/streaks
Ink smears/streaks
Ink smears/streaks
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Carton will not open
Undercount
Carton will not open
Oil spots
Bent/Damaged flaps
Carton will not open
Off color
Oil spots
Bent/Damaged flaps
Carton will not open
Folded flaps
Ink smears/streaks
Folded flaps
Mislabeled
Oil spots
Folded flaps
Bent/Damaged flaps
Carton will not open
Folded flaps
Carton will not open
Folded flaps
Poor ink adhesion
Missing color
Folded flaps
Off color
Folded flaps
Folded flaps
Missing color
Off color
Ink smears/streaks
Ink smears/streaks
Carton will not open
Poor ink adhesion
Carton will not open
Bent/Damaged flaps
Ink smears/streaks
Bent/Damaged flaps
Folded flaps
Folded flaps
Carton will not open
Folded flaps
Carton will not open
Off color
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Mislabeled
Folded flaps
Carton will not open
Bent/Damaged flaps
Fisheye
Bent/Damaged flaps
Off color
Carton will not open
Off color
Carton will not open
Bent/Damaged flaps
Off color
Oil spots
Carton will not open
Folded flaps
Folded flaps
Off color
Folded flaps
Bent/Damaged flaps
Carton will not open
Fisheye
Bent/Damaged flaps
Folded flaps
Bent/Damaged flaps
Off color
Bent/Damaged flaps
Off color
Off color
Bent/Damaged flaps
Off color
Missing color
Bent/Damaged flaps
Missing color
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Carton will not open
Off color
Carton will not open
Folded flaps
Folded flaps
Damaged Pallet
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Ink smears/streaks
Missing color
Carton will not open
Folded flaps
Bent/Damaged flaps
Off color
Oil spots
Carton will not open
Bent/Damaged flaps
Folded flaps
Bent/Damaged flaps
Poor ink adhesion
Carton will not open
Oil spots
Missing color
Bent/Damaged flaps
Bent/Damaged flaps
Damaged Pallet
Folded flaps
Folded flaps
Carton will not open
Bent/Damaged flaps
Carton will not open
Folded flaps
Folded flaps
Folded flaps
Folded flaps
Off color
Folded flaps
Folded flaps
Off color
Bent/Damaged flaps
Off color
Folded flaps
Bent/Damaged flaps
Fisheye
Carton will not open
Carton will not open
Folded flaps
Bent/Damaged flaps
Poor ink adhesion
Carton will not open
Carton will not open
Undercount
Poor ink adhesion
Poor ink adhesion
Carton will not open
Carton will not open
Oil spots
Poor ink adhesion
Oil spots
Bent/Damaged flaps
Folded flaps
Folded flaps
Folded flaps
Folded flaps
Missing color
Folded flaps
Ink smears/streaks
Carton will not open
Carton will not open
Ink smears/streaks
Folded flaps
Carton will not open
Folded flaps
Bent/Damaged flaps
Bent/Damaged flaps
Folded flaps
Folded flaps
Bent/Damaged flaps
Carton will not open
Bent/Damaged flaps
Bent/Damaged flaps
Poor ink adhesion
Bent/Damaged flaps
Carton will not open
Carton will not open
Folded flaps
Poor ink adhesion
Carton will not open
Poor ink adhesion
Bent/Damaged flaps
Bent/Damaged flaps
Bent/Damaged flaps
Poor ink adhesion
Folded flaps
Folded flaps
Folded flaps
Fisheye
Bent/Damaged flaps
Carton will not open
Folded flaps
Folded flaps
Folded flaps
Folded flaps
Bent/Damaged flaps
Carton will not open
Ink smears/streaks
Bent/Damaged flaps
Off color
Folded flaps
Carton will not open
Bent/Damaged flaps
Folded flaps
Carton will not open
Folded flaps
Damaged Pallet
Folded flaps
Folded flaps
Oil spots
 Defects Before Defects After
Improvement Improvement

G 91 9
E 51 45
F 32 30
B 25 27
A 12 10
D 10 10
C 8 6
Other 41 12
 Inspection Report of auto seat cushions Date
Total Seat
Kind of Defect 12-Aug 13-Aug 14-Aug 15-Aug 16-Aug Cushion
Defects 12-Aug
Poor Mix 2 3 1 6 12-Aug
Holes 8 4 7 3 22 14-Aug
Dent 1 5 6 14-Aug
Not enough component 1 1 2 14-Aug
Deformed 1 1 15-Aug
Torn through handling 1 1 2 12-Aug
Oil/grease stains 1 1 1 3 12-Aug
12-Aug
12-Aug
12-Aug
12-Aug
12-Aug
12-Aug
13-Aug
13-Aug
13-Aug
13-Aug
14-Aug
14-Aug
14-Aug
14-Aug
14-Aug
14-Aug
14-Aug
15-Aug
15-Aug
15-Aug
13-Aug
16-Aug
16-Aug
16-Aug
16-Aug
16-Aug
12-Aug
14-Aug
16-Aug
12-Aug
15-Aug
13-Aug
14-Aug
15-Aug
Auto Seat Cushion Defects

Poor Mix
Poor Mix
Poor Mix
Poor Mix
Poor Mix
Poor Mix
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Holes
Dent
Dent
Dent
Dent
Dent
Dent
Not enough component
Not enough component
Deformed
Torn through handling
Torn through handling
Oil/grease stains
Oil/grease stains
Oil/grease stains
 Defects 1st shift 2nd shift 3rd shift Total 10.1% of hose assemblies are defective
Too Short 30 35 26 91 Leadership thinks it's a shift issue.
Too long 44 44 44 132 What issues should be addressed?
Missing threads 10 69 70 149
Leaks 330 321 347 998
Damaged 8 11 5 24
Other 22 20 13 55
Total 444 500 505

O.K. 4508 4495 4481 13484

mblies are defective SPC Simplified, Quality Resources, 1989
s a shift issue.
be addressed?
 Billing Error Number
Incorrect amount 12
Wrong Customer 3
Boulble billing 4
Billing for Unordered Goods 16
Late Billing 5
 Software

Symptom
Abnormal End 5
Address Error 5
Incorrect Output 53
Infinite Loop 9
Error Message 0
Endless Wait 29

Customer Affecting
Software Errors

Allocation Mgt 31
Copying Overrun 13
Pointer Mgt 16
Register Reused 6
Uninitialized Ptr 12
Type Mismatch 10
Undefined State 0
Unknown 0
Synchronization 12

Error Requires
Reboot
Boundary Condition 4
Bug Fix 3
Customer Code 0
Recovery 31
No Trigger 0
Timing 59
Unknown 3

Software Engineering
Days (Source: Capers Jones)
Activities
Testing & Repair 70
Y2K like repairs 50
Cancelled Projects 30
Productive time on projects 47

Defects/Function
Point
Requirements 1.00
Design 1.25
Code 1.75
User manuals 0.60
Bad Fixes 0.40

Page 29
 Accidents by Accidents by
Data Sanity, Davis Balestracci
Department Category
A 5 1 4
B 29 2 2
C 7 3 19
D 3 4 1
E 35 5 13
F 7 6 3
7 7
8 1
9 1
10 5
11 1
13 1
15 6
17 1
18 2
21 5
24 3
26 2
 NASA
Expenditures
Orbiter and Integration 724.5
External Tank 349.7
Main Engine 261.9
Reusable Solid Rocket Motor 418.3
Solid Rocket Booster 137.5
Mission Launch Operations 780.9