Problem Solving Tools Pareto Analysis

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C i p l a L t d I n d o r e S E Z 7Q CTools

Pareto Analysis

Training on


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Pareto Diagram

1. What is Pareto diagram ?

It is a combination of bar and line graphs ofaccumulated data.

It is based on 80/20 principle i.e. 80 % of problems

occurs due to 20% of problem categories.

2. When to use Pareto diagram ?

When there are large number of issues or problems in

give areaShop Floor, office, lab etc

In above situation Pareto Diagram is one of the besttechnique to Prioritize the number of available issues or

problems


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61

36

21

10

1 1 1

47%

74%

90%

98% 98% 99%100%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

0

Occurrence

Frequency

Type Of Issues - Problems

Pareto Diagram illustrative Example

Occurrence Frequency

Cumulative %


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61

36

21

10

1 1 1

47%

74%

90%

98% 98% 99%100%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

DefectQua

nity

Defect Categories

Defects Found In Pack Stock Prazocip sxl 16 - Dec 2011.

Defects In Pack Stock

Cumulative %

Pareto Diagram Prioritization Based On Occurrence Frequency

Defects In Pack StockDefect

Quanity% Quantity Cumulative %

Black Spot/Particle 61 46.56% 46.56%

Torn/Cut Pocket 36 27.48% 74.05%

Other defects 21 16.03% 90.08%

Blister Knurling 10 7.63% 97.71%

Blister Overprinting 10.76%

98.47%Extra foil 1 0.76% 99.24%

Outer carton overprinting 1 0.76% 100.00%


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Pareto Diagram Prioritization Based On Frequency & Criticality

183

72

40

21

5 4 2

56%

78%

90%

97% 98%99% 100%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

50

100

150

200

250

300

Criticality

Score

Defect Categories

Pareto -Defects Found In Pack Stock Prazocip 5xl. 16 - Dec - 2011

Weighted Score

Cumulative %

Defects In Pack StockWeighted

Score

Defect

Quanity

Criticality

1- 5 Scale% Score Cum. %

Black Spot/Particle 183 61 3 55.96% 55.96%

Torn/Cut Pocket 72 36 2 22.02% 77.98%

Other defects 21 21 1 6.42% 84.40%

Blister Knurling 40 10 4 12.23% 96.64%

Blister Overprinting 5 1 5 1.53% 98.17%

Extra foil 2 1 2 0.61% 98.78%

Outer carton overprinting 4 1 4 1.22% 100.00%


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How to Apply Pareto Diagram

a) Finding 20 % of products causing 80% of customer

complaints.

b) Finding 20% of products accounting 80% of dispatch

volume or 80 % of profit.

c) Finding 20% of possible causes of delays accounting

80% of delays in schedule.

d) Finding 20 % of inventory which occupies 80% of total

warehouse space.

e) Also finding 20% of suppliers which accounts for 80%of inventories.


7/24C i p l a L t d I n d o r e S E Z 7Q CTools


1. To identify & reduce defects in Strip/Blister or Bottle

Packing

a) Collect data on Defects found during Pack stock

inspection, say for last 3 months.

b) Create Product wise Pareto Diagram for total no. of

defects found in each product.

c) Select top 2-3 products contributing approximately

80% of total no of defects.

d) Create Individual Pareto Diagram for each of product

For all the campaigns - Overall

Batch Wise


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1. To identify & reduce defects in Strip/Blister or Bottle

Packing

e) Select top 3 high frequent defects across the batches.

f) Perform Root Cause Analysis usingWhy -Why &

Cause & Effects Analysis

g) Identify Corrective Action based on above analysis.

h) Implement the above identified action & Perform

Pareto Analysis again to see the effectiveness of

Action Implemented


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2. To identify & reduce Minor Stoppages (Less Than 5

Minutes) along the Packing Line

a) Collect minor stoppages data shift wise & Line wise

Collect data on Brief Stoppage Description

frequency of occurrenceapproximate total duration

b) Create Shift wise & Line wise Pareto Diagrams.

c) Create Weekly - Overall Pareto Diagram

d) Compare shift wise Paretos to find top 3 high

frequent stoppages for given line & Product


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2. To identify & reduce Minor Stoppages (Less Than 3

Minutes) along the Packing Line.

e) Perform Root Cause Analysis usingWhy -Why &

Cause & Effects Analysis

f) Identify Corrective Action based on above analysis.

g) Implement the above identified action & Perform

Pareto Analysis again to see the effectiveness of

Action Implemented


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3. To identify & reduce Major Stoppages (Less Than 3

Minutes) along the Packing Line.

a) Exactly similar approach as explained in Example 2

to be used for identifying & reducing Major

Stoppages along the Packing line


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Pareto Diagram Application Example 1


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Pareto Diagram

7. Usage of Pareto Diagram? Identify & Prioritize problem.

Find out effect of action taken.Previous & after

improvement Pareto

To drill down in prioritized problem categories

In above Pareto of Unplanned Stoppages, around 70 %

of stoppages are due to 30 % of categories i.e. others,

Blister collection & machine settingscartonator.


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Pareto Diagram

6. How To Construct Pareto Diagram?

Excel Template method

a) Select the type of data to be analyzed for. Eg. Here

Unplanned stoppages at Line No 5 of tablets

packing is considered

b) Use this template to prepare Pareto Diagram.


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Pareto Diagram Exercise:

Sr.

No.

Line Stoppages

Major

Duration In

Minutes

1 Start up 30

2 Foil Change 5

3 Machine Setting

Blister

20

4 Foil Change 15

5 Machine Settings

Blister

25

6 Meeting 707 Defoiling & Rejects 15

8 Foil change 10

1. Perform Pareto analysis for following Line stoppages

Data. Line No: 16.Date: 23- Oct-2011. Shift: 1st


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Sr. No. Line Stoppages

Major Duration In Minutes

1 Batch Change 30

2 Line clearance 15

3 1st Print Proof 35

4 In Process Check 105 Machine Setting - Blister 10

6 QA observation 15

7 Foil Change 20

8 Machine Setting - Blister 25

9 Officer Not Available 35

10 Blister collection 15

2. Perform Pareto analysis for following Line stoppages

Data. Line No: 15.Date: 04- Nov-2011. Shift: 2nd

P Di E i


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Sr. No. Line Stoppages Major Duration In Minutes

1 Cotton Insertion Issue 0.75

2 Cotton feeding pipe Issue 7.33

3 No cotton feeding 0.25

4 Sachet Roll Struck inside

Machine

8.5

5 Silica Roll winding issue 2

6 Bottle Struck below Silica M/C 1.7

7 Bottle Overfilling issue 0.58 Tablet struck in capping M/C 0.33

9 Cap loading 1.25

3. Perform Pareto analysis for following Minor stoppages

Data. Line No: 02.Date: 22- Dec-2011. Shift: 1st

P Di E i


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3. Perform Pareto analysis for following Minor stoppages

Data. Line No: 16.Date: 21- Jan-2012. Shift: 1st

Sr. No. Reason For Stoppage FrequencyDuration -

Minutes

Avg Duration -

Minutes

1

Leaflet missing issue & Leaflet

partial folding issue. Breakdown

Maintenance

1 120 120.0

2 Leaflet Missing 2 1.5 0.8

3 Clearing Leaflet & Blisterrejection

1 2.33 2.3

4 Carton setting at conveyor 1 0.5 0.5

5 Checkweigher stoppage 7 4.8 0.7

6Dent mark on carton during

Carton Packing2 3.8 1.9

7 Carton obstruction at conveyor 1 0.5 0.5

8 Carton flaps not getting closed 5 9.25 1.99 Carton Obstruction at Outfeed 6 2 0.3

10Droppage of cartons from carton

feeding belt to conveyor2 1 0.5

P t Di E i


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C i p l a L t d I n d o r e S E Z7Q CTools


Sr. No. Defects Categories No. Defects Found

1 Outer Carton Overprinting 4

2 Missing Leaflet 2

3 Blister Overprinting 3

4 Broken Tablet/Capsule 2

5 Black Spot/Black Particle 2

6 Chipping/Picking 5

7 Seal open 2

8 Torn Pocket/Cut Pocket 79 Blister / Strip Wrinkles 9

10 Sticker Label Wrinkles 3

4. Perform Pareto analysis for following Pack Stock

Inspection Data.

Problem Solving Tools Pareto Analysis

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