Analyzing The Production Process Of Tom Pullings Toys

Submitted By therec
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Operations Management
Individual Portfolio 3
Report

Brief Summary

This report aims to analyze the production process of Tom Pullings Toys. Tom Pulling Toys manufactures and sells dolls recently the company has encountered a few issues with the production of dolls. For me to analyze this issue, I have used two different Statistical Process Control methods.
The Performance Chart (P-chart) is used to count the number of defects. Often a company’s production method can be sometimes good or defective. The Control Chart (C-chart) is a chart that is used to study the process of changes over time. By using this method I will be able to establish how many defects or issues the manufacturers have encountered.

Table of Content

Brief Summary 1
Introduction & Problem Description 2
Methodology & Results 3
C-chart Analysis 4
P-chart Analysis 5
Discussion and Recommendations 6
Bibliography 6
Apendix A, P-chart Data Results 7
Apendix B, C-chart Data Results 8

Introduction & Problem description
This operations management report will focus on Tom Pulling Toys, which is a major global manufacturer of educational toys for children. Tom Pullings produces over two hundred diverse types of toys in its plant in China and sells them through most of the major retailers in Europe and the USA. The company’s headquarters is based in London, UK. In the recent years Chinese manufacturers have developed further and increased their market share thus revenue and profit for Tom Pullings Toys has decreased.
To stop this trend the CEO of Tom Pullings Toys has introduced a new company-wide quality and efficiency improvement strategy. Their main aim is to identify customer needs and then satisfy these more effectively. They also have to diminish waste at each level of the organization. The company has adopted a range of quality management tools related with the Total Quality Management. The main one of these tools is Statistical Process Control. They want to use this to measure the performance of their manufacturing processes to guarantee that these will meet the obligatory standards. The main reason for implementing Statistical Process Control is the recent number of high customer returns due to inconsistent colouring and the size of the dolls they manufacture.

Methodology & Results
The statistical process control (S.P.C) is a way of arranging the variables that can be part of the success or failure during a process. The methods used by S.P.C determine the compatible product and the efficiency used by the production line. The charts that I will be using in order to determine the issues with the Tom Pulling Toys are the P-chart and the C-chart.
Below we can see the control Chart. The control chart has a central line, which is called the average, an upper line which controls the upper control limit and lower line which controls the lower control limit. These lines show the data which is initially plugged. By comparing the current data with these lines, we can draw conclusions about whether the process variations are reliable or unstable.

C-chart Analysis

Looking at the results after inputting the data samples, it is clear to see that there are issues with the production process of Tom Pulling Toys. The data shows that the process is not fully in control as some samples are very close to the upper limit line or on the upper limit line. This means that the production process is not controlled on an efficiency level.
Although there can always be mistakes on the production line, which are inevitable, but by administrating efficient observation and changes in that particular production process it will not be difficult to correct the fault or errors.

Results C-chart | | | | Xbar | Range | x-bar value | 45.93666667 | | | | | R bar | | 0.553333333 | | | | Upper control
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