- Construct a Fishbone Diagram
PROBLEM: Unable to meet the production quota resulting to opportunity loss
CAUSES: High Rate of absenteeism (Laziness of workers)
Idle Time of Workers (Laziness)
Shortage of Materials
Due to under-stock (supplier’s problem)
Insufficient Number of Trucks (supplier’s problem)
Longer Machine Downtime
Lack of Technician (Machine cause)
Bottleneck
Poor Layout
DATA:
The company operates 9 hours a day with one hour organized lunch break
Total working days per month is 20 days
Production Quota is 40,000 units per day
Actual Output is 16,000 units per day
Rate of absenteeism is 8 workers per day
Machine Capacity is 4000 units per day per machine for 8 hours
Total number of workers is 50 workers (based on required quota)
Lost units due to under-stock of materials is 2000 units.
Truck capacity of 2000 units of raw materials equivalent to 1000 units of production output (2:1 ratio of raw materials to output)
There are 8 available trucks instead of 14 trucks for the required units of raw materials
Machine repair takes 4 hours per breakdown
There is only one machine technician available causing longer machine repair time
5 persons per day (Idle 50% of their time)
Lost units due to Bottleneck is 1,600 units
Lost units due to Poor Layout is 2,000 units
Table 1. Data on Machine Breakdown (Per Day)
No. of Machines Down per day
|
2
|
No. of Breakdown per machine
|
1
|