Situation In the March 2002 Brain Teaser, Donna analyzed data on the percent of electrical instruments that pass the first test. She discovered that the process is predictable at an average of 47%. Now she is determined to get to the root causes of the failures that occurred during the first test. Her goal is to improve the percentage of parts that test good on the first try in order to cut down on rework. To work on the root causes of the failures, Donna set up a team to help collect and analyze data. The first step was to document the measurement procedure so that the testing would be done consistently. Available data A new data collection form was designed that includes information previously collected on the number of failures, as well as the causes of failures at the first test. The team began collecting the new data during the first week of the year. Data for the past 10 weeks are shown in the table, “Failure Data for Instrument AFE 7983.” Questions 1. How does the current behavior of this process compare to the behavior based on the previous data? See the March 2002 Brain Teaser for the data. 2. How can you use the details for the causes of rejection of instruments to determine the root cause? 3. Consider the specific causes of rejections and brainstorm about what step in the process the problem is occurring.
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