SATHISHKUMAR MUTHUKUMAR (1001540196)

ASSIGNMENT-4
2. A project team is studying the downtime cost of a soft drink bottling line. Data analysis in thousands of dollars for
a three-month period are: back-pressure regulator, 30; adjust feed worm, 15; jam copper head,6; lost cooling, 52;
valve replacement,8; and other, 5. Construct a pareto diagram.
Answer: Arranging the processes in descending order:
Lost cooling=52; Back-pressure regulator=30; Adjust feed worm=15; Valve replacement=8; Jam copper head=6; Other=5

4. A major DVD-of-the-month club collected data on the reasons for returned shipments during a quarter. Results
are: wrong selection, 50,000; refused, 195,000; wrong address, 68,000; order cancelled, 5000; and other, 15,000.
Construct a Pareto diagram.
Answer: Arranging the reasons in descending order:
Refused, 195,000; wrong address, 68,000; wrong selection, 50,000; other, 15,000; order cancelled, 5000.
6. Construct a Pareto diagram for the analysis of internal failures for the following data:
Answer: Arranging data in descending order

Type of Cost Dollars (In thousands)

Operations-rework 355
Purchasing-rejects 205
Design-scrap 120
All other 65
Purchasing-rework 25

11. Design a check sheet for the maintenance of a piece of equipment such as a gas furnace, laboratory scale, or
computer.
Answer: Check sheet for the maintenance of a gas furnace:
Defects in Jan-Mar Apr-Jun Jul-Sept Oct-Dec
Burner 11 111 1111 1111 1
Heat Exchanger 11 1 11
Control system 11 1
Air filter 1111 1 11 1111 111
Motor 1 111 1111
12. Construct a flow diagram for the manufacture of a product or the providing of a service.
Answer: Flowchart for a pencil manufacturing company

Shipment receive

Fail
Inspection Shipment return

Pass

Storage

Cutting

Painting

Fail
Inspection

Pass

Polishing

Name printing

Grouping

Fail
Inspection

Pass

Packaging

Dispatch
13. Using EXCEL program file, solve exercise 2.
Answer:
9. Construct a cause-and-effect diagram for bad coffee from a 22-cup appliance used in the office.
Answer: Diagram made in MS PowerPoint.
Team members:
1. Sathishkumar Muthukumar
2. Shishir Kumar
3. Jeel Jose
4. Amanda Abreo
5. Abhijeet Hange
6. Akul Raval
7. Mohammed Saif Khan