Industrial Quality Control Case Studies Excerpt

A Case Study on Identifying the Causes of Delays in the Production of Upper Sole Part of the Shoe in
Maritalia Manufacturing Inc.

Objective/s:

The case study was conducted to identify which of which are the factors that greatly affects the delay in
the production of upper sole part of the store.

Abstract:

The case study conducted to identify which of which are the factors that greatly affects the delay in the
production of upper sole part of the shoe. The study limits itself in thee Stitching and Cutting and Skiving
Department of the Maritalia Manufacturing Inc.

The students used Pareto Analysis and Fishbone (Ishikawa) Diagram as their main tools in interpreting
data they have gathered through direct observations. By observing 35 pairs of 2 inches and 100 pairs of
26.5 inches shoe size, the students were able to point out the most frequent defects occurring in the
production of the mentioned product.

The final results of data interpretation convey that the top three most frequent defects were: trimming
of the leathers; damaged leathers; and excess thread used. Due to this, the students found out that the
primary cause for the delay of production was human error.

Therefore, the students highly recommend the workers to undergo proper trainings and seminars to
improve their efficiency and accuracy inn doing their respective tasks. Also, the workers seat along the
conveyor must be arranged alternately to avoid bottleneck in the assembly line.

Quality Control Analysis of Defective Pistols in Arms Corporation of the PhilippinesFirearms

Department

Objective/s:

Identifying the main problems being encountered by pistol under the bases in the Quality Assurance Line
which includes functioning, machining, and fishing.

Abstract:

Pistol is a type of handgun. Some handgun experts and dictionaries make technical a distinction that views
pistols as a subset of handguns; others use the terms interchangeably. Sometimes in usage, the term
pistol refers to handgun having one chamber integral with the barrel, making pistols distinct from the
other main type of handgun, the revolver, which has a revolving cylinder containing multiple chambers.

Having defects in the output of the products is one of the major problems being encountered inn the
company and it must be prioritized to avoid such wastes and profit loss in the company and its status
when it comes to quality. Thais why the researchers conducted a study to determine the number of
defects of pistol under the firearms department of Arms Corporation of the Philippines.

In this study, the researchers were able to identify the main problems being encountered by pistol under
the three bases in the Quality Assurance line which includes functioning, machining and finishing. In this
way, the researchers recommend such solutions to avoid having defective pistols and its effects in the
production and profit of the company.

Loading and Unloading Activities that Causes Delays in the Humabon Distributors Inc.

Objectives/s:

The case study was conducted to determine the major problems that cause delays both in loading and
unloading activities in Humabon Distributors Inc. It also aims to answer the causes behind those problems,
and the reason why those circumstances happened and its impact towards the company.

Abstract:

The case study was conducted in order to determine the major problems that cause delays both in loading
and unloading activities in Humabon Distributors Inc. and if these problems can be solved, it is going to
be helpful to the company and it is going to help the skill and intellectual development of the
aforementioned students in using the quality control tools. Through this, the study practitioners also
aimed to know the causes behind the problems, and the reasons why those circumstances happened and
its impact towards the company.

The study limits itself to analyze the problems causing the delay in the loading and unloading activities in
Humabon Distributors Inc. by knowing the role of the workers, transportation and the warehouse design
in the delays in the activities. The study practitioners also focus in finding out the causes why the problems
occurred.

The necessary data was obtained through observation and time and study motion. Time study motion was
used in order to determine the standard time of the workers in completing their tasks. The data gathered
was analyzed though Pareto Diagram Analysis, a statistical techniques used to identify the various factors
that contribute to an overall effect. Fishbone Diagram Analysis was also used in this study; it is used to
identify potential factors causing an overall effect.

The Pareto Diagram Analysis results obtained from the two-day observation and the time and motion
study showed that there are three major problems that cause delays in loading and unloading activities
in the company which are: (1) incomplete stocks, (2) not well-arranged stocks and (3) improper staging
stocks. The Fishbone Diagram Analysis identified the major root causes of the delays in Humabon
Distributors Inc. Those were classified as ma, method, equipment and the warehouse supervisors and the
management with their warehouse personnel cause the problem inn the man category. The equipment is
all not in good working conditions due to poor maintenance. The space in the warehouse is not big enough
to accommodate all stocks. And improper ways of handling is one of the root causes in the method
category.
The results obtained in the study led the study practitioners to believe that having enough manpower in
the loading and unloading of the products will make it easier for the company and well-organized
workstations improve the productivity of the workers. Having a well-organized warehouse will also enable
more space for the products to be stored. There are different factors that also affects the workers, these
are fatigue, working condition, time of the day and personal factors which cause their poor performance.
With this case study, it would be possible to improve the warehouse and workers performance of the
Humabon Distributors Inc.

Application od Ishikawa (Fishbone) Diagram in Identifying the Problems in the Production Area that
Contribute to the Delay in the Delivery of Candles to the Customers During Peak Season

Objective/s:

Generally, this study aims to determine the problems in the production of New Miracle Candle
Manufacturing Corporation during peak season that results to delayed delivery of orders to customers.
More specifically, this study addresses the problem through the following:

a. To assess the work of different production sections, occurrence of delays, and their
magnitude
b. To determine the problems in the production that results to delivery delay during peak season
c. To understand the various aspects in candle manufacturing that causes the problems in
production

Abstract:

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Case Study: Defects Analysis of Maritalia Manufacturing Products Using Quality Control Tools

Objective/s:

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Abstract:

The case study was conducted in order to identify defects that occur in the products during manufacturing
process and thee frequency of its occurrence, as well as to trace and to determine the factors contributing
to the aforementioned defects. Through this, the proponents expect to provide a concrete solution that
will eliminate these defects or if not possible, to minimize its occurrence. The study would be beneficial
in the cost reduction and process improvement of the Maritalia Manufacturing Inc. This study was
conducted mainly to further develop the Quality Control of the company.

This study limits itself on the Quality Control, specifically the analysis of the defective products occurring
on the finishing department of Maritalia, Conception for the month of September 2016. The paper also
provided an objective SWOT (Strengths, Weaknesses, Opportunities and Threats) Analysis of Maritalia.
Obtaining of necessary data was done with the help of the Quality Control personnel of Maritalia who
provided a written report pertaining to defects that occurred and discerned during the manufacturing
process. The data gathered was used in the construction of the Pareto Analysis as well as the Fishbone
Diagram.

The Pareto Diagram showed that Off-shade and scratch on the outer Part of the Shoes is the largest
contributing factor of the defects that occurred in Maritalia. The Fishbone Diagram consists of the factors
that the proponents believed to be causing the said defects.

Application of Quality Control Tools for Assessing Unwanted Errors on the Production of Confectionery
Department (NIPS) A Case Study on Universal Robina Corporation, Canlubang, Laguna Plant

Objective/s:

1. To be able to provide a possible solution to solve the problem in the unwanted errors in the
production
2. To provide a possible solution to get the highest feasible production.
3. To determine the main cause of the problem using Fishbone Analysis as the quality control
tool on the assessment of the unwanted errors in Confectionary Department (Nips)

Abstract:

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A Case Study: Improving Warehousing, Fabrication, Installation, and Maintenance Processes Using
Quality Control Tools in Ener-G-Tech Engineering Services and Trading

Objective/s:

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Abstract:

This case study entitled Improving Warehousing, Fabrication, Installation and Maintenance Processes
Using Quality Control Tools in ENER-G-TECH Engineering Services and Trading aims to determine and
identify the different types of occurrences and causes of defects on warehousing, fabrication, installation
and maintenance processes present in ENER-G-TECH.

The problems that arise in different services in the company were established and analyzed by using
Quality Control Tools such as Pareto Diagram, Fishbone (Ishikawa) Diagram and Check list. The researchers
gathered information and data about each problems that are present on different services offered by
ENER-G-TECH. Through the use of the gathered data, the researchers discovered the primary causes of
defects and problems that are frequently experienced by the workers.
An Application of Pareto Analysis and Ishikawa (Cause-Effect) Diagram for Machine Defect Minimization
at the Printing Department of Ace Print Master and General Merchandising, Inc.

Objective/s:

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Abstract:

ACE Print Master and General Merchandising, Inc. (APM) is a business center that offers a wide variety of
services such as printing, photocopying, advertising, etc. As of the present, there has been an increase in
customer dissatisfaction with the printing department of the company because of output defects, which
resulted to a significant amount of loss on the company. Based on a series of interviews conducted with
the staff and the General Manger of the company, the researchers deduced that the root cause of these
inadequacies is the machines. This study aims to determine the machine defects that greatly affect
companys services and printed outputs, and to evaluate the frequency of each machine defect with the
use of Pareto Analysis. Also, Ishikawa (Cause-Effect) Diagram was used to identify the major causes behind
the machine defects at the printing department of ACE Print Master and General Merchandising, Inc. The
findings of the study are: the two most frequent printing machine defect types are machine overheating
and machinery breakdown, and the two most frequent photocopy machine defect types are paper jams
and misfeeds. Suggestions and recommendations for the improvement of the machines, services and
products of the company were also provided in this study.

Application of Industrial Quality Control Tools for the Assessment of Delayed Delivery of Cap Seals: A
Case Study on Polyseal and Empire Manufacturing Industries

Objective/s:

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Abstract:

This case study entitled Application of Industrial Quality Control Tools for the Assessment of Delayed
Delivery of Cap Seals: A Case Study on Polyseal and Empire Manufacturing Industries aims to give a hand
to the company in analyzing and determining the problems that causes the delay in the delivery of cap
seals, and to identify the rightful solutions to these causes.

The possible origins of the problem in the delivery delay cap seals were identified by the use of Quality
Control Tools, specifically the Fishbone Diagram and were examined thoroughly by Pareto Diagram. The
proponents gathered the data that were necessary to scrupulously examine the identified causes. With
the collaboration of the company, it was made possible to gather more accurate records that led the
proponents to succor the company in eliminating the problems that causes the delay in the delivery of
cap seals.

Loading Effects in Pistol and Rifle Ammunition

Objective/s:
Nothing to show

Abstract:

The purpose of this study is to investigate the three main cause of loading defects in pistol and rifle
ammunition and also, to provide recommendation to solve the Department of the Arms Corporation of
the Philippines in Marikina City.

Interviews were conducted with the four operators of four different machines; the two were from the
5:56 MM operation and the other two were from the 38 SPL operation. And the other data are being
gathered through observations. The data gathered were statistically analyzed by Pareto Chart and
Ishikawa Diagram.

It was concluded that the three main cause of loading defects are the body dents, defective mouths, and
cartridges with out of range height and to solve these problems, the researchers suggests that the
operators should be advised to separate the as-received material defects and loading process defects, the
machines should be properly maintained and must be clean before using it in the operation. Also, a more
skilled inspector is needed to classify mouth defects in 5.56 mm case and cartridges. Analysis loading
defects in other cartridges is recommended.

A Case Study on the Form Defects Encountered on the In-Process Inspection at Trojan Computer Forms
Manufacturing Corporation

Objective/s:

The objective of the study is to learn and have a real experience or situation analysis on the quality control
department of Trojan Computer Forms Manufacturing Corporation.

The following are the objectives the researchers want to achieve:

1. To analyze the current situation of the companys quality control

2. To identify the number of defects encountered during printing process
3. To enable to generate specific solutions that would lessen the defects
4. To present the outcome and make recommendations to the management

Abstract:

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Quality Control Analysis of Powder Coating in the Chemrez Technologies Inc.

Objective/s:

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Abstract:
Rejects are a major problem that a manufacturing company usually experience. A tremendous amount of
financial loss may incur to the company if there is a failure in the production and quality inspections of
powder coating. There are several factors that cause these rejects. To know these causes, a thorough
analysis of the process must be done.

Data of this study was gathered through interviews, observations and historical data that are analyzed
using Pareto Analysis and Ishikawa Diagram or Root Cause Analysis.

The researchers aim to identify the possible causes of the quality problems that occur in the
manufacturing process of powder coating. The researchers believe that this study will benefit the
customers, QC department, Production department and the company itself.

An Application of Pareto Analysis and Fishbone Analysis in Assessing Delays in the Production of Jogging
Pants at the Garments Section A Case Study on ACE Print Master and General Merchandising, Inc.

Objective/s:

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Abstract:

Ace Print Master and General Merchandising, Inc., established in March 20, 1994, started as a business
center and a one-stop computer shop located at BF Homes Paranaque City. The company includes
garments as one of its services and it is known that garment industry is a major contributor to the
economies of many countries especially on developing countries such as the Philippines. Industrial
companies commonly experience various problems throughout their manufacturing process. A problem
can be defined as a matter or situation that effects in production performance, product quality and on
time delivery. Currently, the Ace Print Master and General Merchandising, Inc. has experienced
production delays with the manufacturing of jogging pants. By using Fishbone Analysis and Pareto, this
study aims to determine the causes and sub-causes of one particular problem and therefore to list the
causes for the production delay of jogging pants systematically. The findings in this study suggest that
lacking of manpower and the companys worker itself is the major cause of the delay in production of
jogging pants.

Application of Ishikawa Diagram on the Recurring Problems on Expiry Date Codings at Monde M.Y. San
Corporation

Objective/s:

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Abstract:

The proponents aimed to find the root cause of the recurring problems on expiry date coding and
formulating a corrective action for the problem. A Fishbone Diagram was prepared to visualize all possible
causes of the problem. By brainstorming, the proponents tracked down the strongest cause that seems
very plausible. It was the maintenance staff that the proponents think that is causing the recurring
problem. The proponents recommend that there should be another maintenance to double check all
settings for the machine. It is also recommended to install a new program that automatically changes the
expiry date to be printed correctly.

Application of Industrial Quality Cntrol: Pareto Analysis and Ishikawa Diagram on the Sewing and
Ironing Section of Henson Clothing Company, Inc.

Objective/s:

This study aims to determine the following:

1. The major defects in the school uniform pants of Henson Clothing Company Inc. using
Pareto Analysis
2. The causes of the resulted defects using Ishikawa Diagram.

Abstract:

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A Case Study about the Quality-Related Problems of the Products of Convenience Distribution
Incorporated

Objective/s:

This study sought to scrutinize the possible problems that arise from maintaining the quality of freshness
of the products catered by the Convenience Distribution Incorporated, the distributor of Philippine Seven
Corporation which is commonly known as 7-Eleven Incorporated. It aims to evaluate every step of the
process to know the possible factors that affect the quality of the products in terms of freshness,
distribution, and service to the consumers. It also aims to evaluate the problems by the use of quality
control tools.

Abstract:

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Contact Person: Ms. Mary Jane Federis (HR Admin)

An Application of Pareto Analysis and Ishikawa Diagram in Analyzing the Defects in the Bottle of Gluta
C Toner of Ardent World Inc.

Objective/s:

This study aimed to analyze the defects of packaging materials of Ardent World Inc. specifically the Gluta
C Toner using Pareto Analysis. The Pareto Analysis is useful for identifying which areas need to focus for
the resources of the company in order to achieve maximum efficiency.

Specifically, this study intended to achieve the following:

 1. To apply Pareto Analysis which arrange and determine the major defects in the
bottles of Gluta C Toner
2. To construct Ishikawa Diagram that categorizes potential causes and factors that are
related to it that leads to the major problems evaluated in Pareto Analysis
3. To provide some recommendations or solutions that will be able to minimize the
current problem and will improve the quality of the bottles used as packaging
container of Ardent World Inc.

Abstract:

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Pest Control Management in Warehouses of 2GO Group Inc.

Objective/s:

The study aimed the following:

1. To identify the particular pests that can generate problems inside the warehouses of
2GO Group Inc. and to evaluate which type of pest is needed to be given an
immediate pests control action by company
2. To have critical assessment and investigation on the causes of pests that exceed in
PTL based on the construction of Pareto, and Cause and Effect Analysis.
3. To determine the relationship of the elimination of the major causes of pests that
exceed in PTL to the elimination or decrease of other type of pests inside the
warehouses of 2GO Group Inc.

Abstract:

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Company Study at Rejected Raw Materials (Glass and Aluminum) Supplied to Duralco, Inc.

Objective/s:

Nothing to show

Abstract:

The purpose of this study is to identify the defects of aluminum and glass product of Duralco, Inc. By the
use of the acquired defects provided by Duralco, Inc., the researchers used some of the Quality Control
methods to come up with the desired result, the root cause of the defects. The methods used are Pareto
Analysis, Ishikawa Diagram and Streamline Analysis. Through further computation and analyzation of the
given data using Pareto Analysis, the researchers acquire the top 3 defects each aluminum and glass.
Scratches, delays and bubbles/warp or marks with 24, 24 and 13 frequencies respectively are the top
defects for glass, while orange peel, off shade and dents with 16, 14, 13 frequencies respectively are the
top defects for aluminum. These top 3 defects were then used as subjects for Cause and Effect Diagram.
The causes of the defects for aluminum and glass is categorically identified depending on the five factors
of productionman, methods, materials, machine and environment. After establishing the possible cause
of each defect for aluminum and glass, the acquired cause and effect data was then translated into stream
line analysis. With the utilization of this method, the researchers were able to pinpoint easily the most
possible root cause of each defect.

In Glass, the most possible root cause for bot Scratches and Bubbles/Warp or Marks is the lack of the
training of the workers; while Delays s the poor maintenance of delivery trucks. On other hand, the
possible root causes for the top 3 defects from Aluminum; orange peel, dent, and off shade is the lack of
training of the workers.

A Case Study about the Large Volume of Footwear Soles Returned by the Client to Maratex
Manufacturing Corporation

Objective/s:

Nothing to show

Abstract:

The purpose of this study is the following; to determine the root cause of the companys main problem,
which is the occurrence of returned footwear soles; and to an analysis applying the Industrial Quality
Control tools in order to recommend a solution to the main problem. The researchers focused on a
company which produces and distributes different kinds of foot soles which is the Maratex Manufacturing
Corporation located at Marikina, Metro Manila. The researchers used Industrial Quality Control tools
which are mainly Pareto Analysis and Ishikawa Diagram to analyze and evaluate all the collected data to
come up with a conclusion and recommendation for the benefit of Maratex Manufacturing Corp.

Contact Person: Mr. Richard Tiu

Company Study of Appearance Defects of Wood Furniture of Living Concepts Furniture

Objective/s:

The study aims to analyze the defects of furniture products of Living Concepts Furniture and formulate
possible recommendation relevant to the problem using Quality Control Tools

Abstract:

Nothing to show

Root Cause Analysis of Damaged Rack Posts and Beams in Cold Storage Facilities of Igloo Supply Chain
Philippines, Inc.
Objective/s:

Nothing to show

Abstract:

The study was conducted at Manggahan Light Industrial Park, Pasig City. Its purpose is to identify all
probable root causes of damaged rack posts and beams in Igloo Supply Chain Philippines, Inc. cold storage
facilities. Since the pallet racking is one of the valuable components nedded in the cold storage industry,
preserving it is a must. The study aims to help the company to increase their efficiency and productivity
through lessening the occurrence of the dents. Making them cost efficient whilst continuously improve
the quality of their services.

Through an interview with the Quality Assurance Health and Safety Environment (QA HSE) department
manager, safety officers, MHE operators and doing an actual observation in the cold storage facility, the
researchers gathered data. Pareto Analysis, Tree Diagram, 5 Whys and Barrier Analysis were used to
validate the probable root cause of the said dents.

In conclusion, there are three main causes of damaged racks in the facility: Limited visual capacity,
negligence of operator and malfunction of equipment. These identified causes directly affect the physical
state of the racks.

A Case Study of Defects in Truck Bodies of Centro Manufacturing Corporation

Objective/s:

Nothing to show

Abstract:

This study is about the defects in truck bodies manufactured by Centre Manufacturing Corporation. This
study aims to address the causes of defects and give solutions to minimize defective outputs. It will help
the company to minimize costs and improve production process with minimal number of defects in truck
bodies being produced.

The Quality Control Department tallied and recorded defective truck bodies for the month of August, year
2016. With the given data, QC tools namely Pareto Analysis and Fishbone Diagram are used to determine
the causes of the defects in truck bodies.

According to result of analysis, the researchers were able to obtain the top three defects namely, sag
paint, thin paint and crack. in truck bodies and their causes. Specifically, the causes are having unskilled
and pressured workers and also, fatigue during working hours. Use of old spray gun and faulty nozzle
results in having saggy and cracked paint. Poor viscosity of paint, exposure to hot temperature, oil, and
dirt, uneven painting, incorrect painting technique and method. excessive sanding, wrong application of
primer, buffing on corrugated baits, poor mixture of paint, excessive use of solvent, application of coating
over a glossy finish, and top application is dry are the other causes.
From the findings and conclusions, the researchers came up with solutions to minimize the defects. The
management should hire skilled workers, they must check the raw materials before the production, and
also the Quality Control department must do their jobs with high accuracy.

Assessment of the Defects on the Incoming and Outgoing Inspection of Rex Printing Company Inc. for
the Month of September 2016

Objective/s:

This study ought to determine the top defects encountered in Rex Printing Company Inc. with regards to
the:

a. Incoming Inspection for the month of September 2016

b. Outgoing Inspection for the month of September 2016

Abstract:

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