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Business Analytics - Case Study

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Model Year 12 Hydraulic Leak Complaints
19 October 2012

Our dealers began to complain of an increase in hydraulic leak failures. Their complaint was of single machines with multiple leak locations. In some cases, this meant that hoses were falling off the machine, causing a complete loss of hydraulic oil. Company A’s warranty covers the cost of the part as well as standard repair time. These dealers have become increasingly frustrated by this as they are Company Apaying drive time to and from the customer, as well as the cost of the oil.
In assessing this situation, the first step was to verify that the number of leaks was increasing. At the time of the complaints, very little information was available for the current model year. Previous model year warranty data shows a trend of 2.5 Failures Per Machine (FPM) for hydraulic leaks. Taking a sample of 30 domestic machines showed an FPM of 3.2 FPM.
By simply categorizing the failures to the assembly location we could quickly identify the concern areas to the hydraulic pump sub assembly and wheel motor sub assembly station. A team was assembled to monitor these two stations, and found operators who were not following the process. At this time it was also noticed that the process has high risk for failure, based on the team’s experience. We proposed improved processes that the operators could follow. We also proposed to improve the tooling to smart tools. Smart tools would reduce the risk of operator error.
After the process improvement, we analyzed data from 30 additional domestic machines. The analysis showed an FPM of 1.8. Doing a paired t-test we found that the process improvement was not statistically improved. Based on this data, the team again proposes the implementation of the smart tools. As a result of the first analysis, management agreed.

Problem Description
Our customer support department

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