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Seattle Concrete Case

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Submitted By edithz210
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Summary
Seattle Concrete Company (SCC) produces bags of concrete mix for its customers. These bags have a stated weight of 40 pounds per bag. Given the steep penalties for under filling bags, SCC sets a target of 41 pounds per bag to ensure under filling due to natural variations still remain above the 40 pound threshold. Historically, they have operated with a single production shift, but have recently added a second shift to meet their growing demand. Management is interested in a full analysis of their process to ensure that the control limits and capabilities are within reason, and to ensure that the addition of a second shift isn’t causing issues to their process. To accomplish this, a data set was constructed. Ten bags were tested every hour during each of the two separate eight hour shifts. This continued for five days to give us 800 observations, 400 from each shift.
The samples provided were analyzed for management using statistical process control methods, control charts for attributes, and capability analysis. This included X & R control charts, P-charts, C-charts, and capability analysis. The interesting finding was that all the control charts displayed variations and fill levels completely within the limits. Also, defective bags, defined as those filled to less than 40 pounds, occurred within acceptable limits. Despite all this, the capability analysis with our chosen bounds of 40 pounds to 42 pounds failed to meet the 3σ threshold. Upon this determination, we returned to re-analyze our findings, much of which is discussed in the following pages.
One item of particular note was the R chart for the second shift. This shift showed a steady rise in variability throughout each day, capping just below the control threshold. While this meets standards of our test, it still displays an area for improvement. Reducing variability will lower the

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