Manufacturing

Carton Manufacturing Defects

Line 1
Folded flaps
Bent/Damaged flaps
Carton will not open
Poor ink adhesion
Off color
Ink smears/streaks
Oil spots
Fisheye
Missing color
Mislabeled
Damaged Pallet
Undercount

(Quality Digest Dec 2006)

Line 2
16
37
29
7
14

Line 3
6
22
18
8
5
5

83
24
29
18
12
19
14

9
8
3
3
2

Total
Defects
105
83
76
33
31
24
14
9
8
3
3
2

Circuit Board Defects

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

Lost Time Analysis (LTA)

Generator Failure
Conveyor Failure
Training
Safety
Flooding
Pump Failure
Causes of Lost Time
Work Instructions
Bill of Materials
Work Orders
Out of Stock
Wrong parts or material
Lack of tools
Bad assembly
Service Order Rejects
Location 1
Location 2
Location 3
Location 4
Location 5
Location 6
Location 7
Location 8
Location 9

Page 1

Manufacturing

Lost Time
(Minutes)
346
71
34
26
20
9
Incidences
45
40
30
7
7
7
7
Service Order Rejects Lost Time
7564
630
13618
106
2121
37
5121
293
6341
288
7116
710
5212
516
16447
654
6530
504

Description

Scrapped Qty

Ship Qty

Scrap % of Shipped

Support

169

2000

8.45%

Poppet

78

2000

3.90%

Core

135

3500

3.86%

Stainless Body

64

2486

2.57%

Solid Top Axle

197

2.03%

Armature

93

5000

1.86%

Aluminum Washer

76

4970

1.53%

Flange

34

2300

1.48%

Safety Plug

56

4000

1.40%

Neck

79

1.27%

Stainless Washer

11

1037

1.06%

Terminal Cap #8

10

1065

0.94%

Barrel

18

2148

0.84%

Terminal Cap #10

12

1955

0.61%

G30 Front Wearplate

500

0.60%

Low Profile Housing

215

0.47%

Solid Body

303

0.33%

Stainless Washer

1060

0.19%

G20 Wearplate

5046

0.06%

Stainless Washer

2070

0.05%

Page 2

Manufacturing

Tank Defects

Incorrect Dimensions
Parts damaged
Machining
Insufficient masking
Parts rusted
Adhesive failure
Film on parts
Salt spray failure
Out of order
unfinished fairing
Wrong part issued
Weld misaligned
Paint out of spec
Delaminated composit
Voides in casting
Paint damaged
Primer damaged
improper procedure
powdery alodine

36
34
29
17
13
6
5
4
4
3
3
2
2
2
2
1
1
1
1

Page 3

Restaurant Complaints
Cold Food
Flimsy Utensils
Food tastes bad
Salad Not Fresh
Poor Service
Food Greasy
Lack of Courtesy
Lack of Cleanliness

Number
105
20
10
94
15
9
5
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

Lean Six Sigma

Donna Summers
pg 97

Healthcare

Timely Filing
Medical Necessity
No Authorization
Partial Authorization
Invalid Auth for Patient Status

Claim Denied
(No Appeal)
$ 7,849,569
$ 2,516,508
$ 1,295,032
$ 750,766
$ 336,270

Wrong Technique
Wrong Time
Wrong Dose
Wrong Route
Drug not available
Wrong Form
Extra Dose
Unauthoried Drug
Omission

Medicatio
n Errors
Baseline
41
33
5
5
3
3
1
0
0

Orthopedic Surgery
General Surgery
Neurosurgery
Urologic Surgery
Other

Type of Wrong Site or Pati

52
25
18
13
18

Wrong Body Part or Site

Wrong Patient Surgery
Wrong Procedure

Wrong Site or Patient Surg

96
17
13

Surgical Retained Foreign Objects

Sponges
Instrument
Needles
Miscellaneous

# RFOs

Pharmacy
Order not received
Wrong Frequency of Dose
Duplicate order entry
Wrong Dose
Omission Drug
Order not Discontinued
Additional Instructions
Wrong Drug
Wrong Patient
Wrong Route (IV vs Intramuscular)

Order Entry Errors

51
47
20
20
19
13
13
11
3
2

Room Not Read

Doctor Not Ready
Prior Procedure Too Long
Prior Case Add On
Prior Case Too Early
Case Start Early

Missed Start Times in Cath Lab

43
wrong patient
88
wrong procedure
47
wrong side
26
wrong part (60)
84
19

Additional laboratory testing

Additional patient monitoring
Physical disability or mental impairment
Increased length of stay
Major surgery
Transfer to higher level of care
Death
Minor surgery
Other additional testing
System/process delay
To be determined
Hospital admission
Loss of bodily function
Other
Loss of sensory function

NJ Impact of Adverse Events Adverse Event Patient falls in New Jersey Hospital
283 NJ 2007
Falls 2005
270
Patient Room
103
185
Hallway
6
183
Emergency Department
8
121
Radiology
1
91
ICU/CCU/TCU
1
72
Telemetry Unit
1
53
Cardiac Catheterization L
0
38
Rehabilitation Areas
1
38
Other
3
35
23
13
13
10

23
1
3
7

Page 5

Wrong Site or Patient Surg

34
39
298
60

Healthcare
Loss of organ

Page 6

Healthcare

Medicatio Medication
n Errors
Errors
6 months 18 months
25
5
13
16
1
2
1
0
5
4
0
0
3
2
2
1
2
0

Type of Wrong Site or Patient Surgery

Joint Commission Dec 5, 2001

SSN
Name
DOB
Test
Doctor
Other

Lab
Order
Errors
226
71
58
44
39
16

Type of
test
Quantity
Chemistry
22063
Hematolog
5532
Urine
2292
Serology
1043
Bacteriolog
673

Missing Billing Coding and Info

Pharmacy
76
Diagnosis
12
Treatment charge
11
Account type
6
Venipuncture
5
Other
6

Wrong Site or Patient Surgery

Joint Commission Dec 5, 2001

Wrong Site or Patient Surgery

lls in New Jersey Hospitals

Falls 2006 Falls 2007
132
152
12
14
12
12
3
4
3
4
0
4
2
2
2
2
2
2

Drug Use Volumne and costs

Drug
Cost/unit Units Used Total Cost ($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
H
650
169
110
I
220
114
25
J
15
1333
20
K
56
1518
85
L
150
1367
205

Page 7

Healthcare

Page 8

Healthcare

Adverse Events
infection
Injury
Mycardial infarction
Deep vein thrombosis
Fall
Pressure Sores
Rash
Breathing Problems
Confusion
Dizziness
Drop in Blood Pressure
Nausea
Pain
Other responses
Other events
total

Medication
New
Effects of Effects of
management Medications surgery
tests
Other
0
0
38
6
0
3
84
6
0
0
9
2
1
0
9
1
1
0
3
1
0
0
6
0
0
71
3
5
1
7
18
0
1
27
3
0
1
40
0
0
3
25
23
3
2
70
0
5
9
0
9
7
37
91
0
6
0
3
84
30
56
337
289
72

Medical Error
Pharmacy
Clinician
Nonmedical Error
Insurance or billing
Scheduling
Wrong Information
Prescription Delay
Test results delay
Behaviour/Communication
Waiting time
Clinician disrespect
Staff disrespect
Felt rushed
Technician care
Other
Misunderstanding
Medical Care
Medication side effects
Clinician unhelpful
Scheduling
Ordering
Insurance Coverage
Missing documentation

Patient Reported Errors

26
12
14
22
7
6
6
2
1
49
18
11
8
4
2
6
112
71
15
11
7
4
3
1

Page 9

7
3
7
1
11
7
13
8
0
1
9
0
3
1
20
91

Healthcare

Page 10

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 11

Healthcare

Page 12

Defect
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

<-- Click the heading and then click Pareto Chart

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

Inspection Report of auto seat cushions

Date
Kind of Defect
12-Aug 13-Aug 14-Aug 15-Aug 16-Aug Total Seat C 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
Too Short
30
35
26
91
Too long
44
44
44
132
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

10.1% of hose assemblies are defective

Leadership thinks it's a shift issue.
What issues should be addressed?

mblies are defective

a shift issue.
be addressed?

SPC Simplified, Quality Resources, 1989

Billing Error
Incorrect amount
Wrong Customer
Boulble billing
Billing for Unordered Goods
Late Billing

Number
12
3
4
16
5

Software

Abnormal End
Address Error
Incorrect Output
Infinite Loop
Error Message
Endless Wait

Symptom
5
5
53
9
0
29

Allocation Mgt
Copying Overrun
Pointer Mgt
Register Reused
Uninitialized Ptr
Type Mismatch
Undefined State
Unknown
Synchronization

Customer Affecting Software Errors

31
13
16
6
12
10
0
0
12

Boundary Condition
Bug Fix
Customer Code
Recovery
No Trigger
Timing
Unknown

Error Requires Reboot

4
3
0
31
0
59
3

Software Engineering Activiti Days

Testing & Repair
Y2K like repairs
Cancelled Projects
Productive time on projects

Requirements
Design
Code
User manuals
Bad Fixes

(Source: Capers Jones)

70
50
30
47

Defects/Function Point
1.00
1.25
1.75
0.60
0.40

Page 26

A
B
C
D
E
F

Accidents by Department
5
29
7
3
35
7

1
2
3
4
5
6
7
8
9
10
11
13
15
17
18
21
24
26

Accidents by Category
Data Sanity, Davis Balestracci
4
2
19
1
13
3
7
1
1
5
1
1
6
1
2
5
3
2

Balestracci

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