Question: Assignment Pareto Chart Dorf Motors has been experiencing problems with the installation of seats on its auto assembly line. A recent study showed the number
Assignment Pareto Chart Dorf Motors has been experiencing problems with the installation of seats on its auto assembly line. A recent study showed the number and type of problems over the last week of production. Problem TypeFrequencyIncorrect seatFabric tornFabric stainedSeat improperly mountedSeat positioning problemsElectronics reworkSeat does not fit When a problem is discovered, the car is tagged for rework. Workers in the rework area earn $ an hour. Each seat costs $ if it has to be scrapped. Incorrect seat means that the incorrect type of seat was available on the assembly line. For example, a black leather seat may have been next in line to be installed, but the seat type should have been a red cloth. Similarly, the seat may have been a sixway adjustable power seat when a manual adjust seat was called for. This requires one half labourhour of work in the rework area to complete all the necessary paperwork and to replace the seat. The incorrect seat is later installed in the type of car for which it was intended, so the seat is not a writeoff. Fabric torn means that, at some point in the process, a tear was discovered in the seat fabric. This may have occurred at the time of installation or later during the assembly process. In this case, the seat must be scrapped. Scrapping and replacing requires labourhour. Fabric stained means that, at some point in the process, a stain was discovered on the seat. This may have occurred at the time of installation or later during the assembly process. A worker can attempt to remove the stain. This requires an average of minutes and is successful of the time. If stain removal is unsuccessful, the seat must be scrapped and replaced. Scrapping and replacing requires a further labourhour. Seat improperly mounted means that the seat was simply not mounted to the vehicle frame correctly. This requires only an average of minutes of labour to correct. Seat positioning problems means that, during final inspection, it was discovered that the adjusting the seat position in the vehicle is difficult, if not impossible, due to some obstruction. This requires labourhour to fix. About of the time, the seat must be scrapped and replaced requiring an additional labourhour. Electronics rework means that there is the electronics portion of the seat is not working correctly for example, the heated seats do not work This typically requires the most time to complete: an average of minutes. The seat does not have to be scrapped. Does not fit means that the seat does not fit properly within the cockpit, but instead is brushing or rubbing up against some part of the interior most commonly, the gear shift console This requires labourminutes to scrap and replace the seat. The $ cost of the seat is not incurred by Dorf since this is due to a supplier manufacturing defect. The labour cost is incurred, however. a Complete a Pareto chart using only defect frequencies. What defect class does the chart suggest should be tackled first? b Complete another Pareto chart, this time weighting the defects by the cost that Dorf Motors incurs. Does the priority sequence change? What defect class does this chart suggest be of primary importance? c Which chart do you think is the better way to prioritize? Why? Can you come up with a reason why the other chart type would be preferable? Note: You may not be able to figure out how to get the percentage cumulative line on the chart. Thats ok Ill settle for just the bars.
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