Weight Tolerances Continuous Improvement Project

Liturgical Publications Inc.Because Vibrant Churches Matter

INTRODUCTION

TEAM

Project Owner: Jeanne Krien

Manager: Ken Pranger

Project Sponsor: Tracey Rogers

Advisor: Prof. Alireza Kabirian

Team: Anuj Bindagi

Bhanu Poreddy

Joanna Rumbley

PROFILE

Product: Church Bulletins

Accounts: Approximately 800

Volume: Customer order (Varies)

Time: Weekly

Current Issue● Wrong shipment to wrong

account● Less or more quantity than

ordered

PROBLEM

GOAL

To Establish Acceptable Range of Weights for Shipped Packages by

Account

Our Approach

04 Improve

01 Define

02 Measure

03 Analyze

05 Control

Define

Establish a target weight for orders based on:

1. Quantity of bulletins (including overage)

2. Paper type

3. No of pages in a bulletin

4. Weight of the box

Define

SHIPPED WEIGHT▪ Checked at shipping

COMPARE

THEORETICAL WEIGHT RANGE▪ Formula based calculation

Measure

Paper▪ Regular▪ Gloss

Paper Size▪ 11X17 (4 Pg)▪ 11X22 (5 Pg)▪ 11X25.5 (6 Pg)

Printing▪ Inkjet▪ Offset

Box Size▪ AA ▪ B ▪ C ▪ D

Measure

Available Data

▪ Order Quantity ▪ Quantity Printed ▪ Quantity Shipped

▪ Paper Type ▪ Paper Size ▪ Printing Type

▪ No of Boxes Shipped

▪ Shipped Weight ▪ Number of Pages Per Bulletin

Weight of one sheet of paper for Gloss and Regular and for all three

paper sizes

DATA CALCULATED

Measure

Weight of 4 types of Boxes

Analyze

Analyze

Analyze

Analyze

▪ Calculated weight = (Number of pages in one order) X (Weight of one page)

▪ Lower limit = (Calculated weight) + (Number of boxes) X (Weight of AA box)

▪ Upper limit = (Calculated weight) + (Number of boxes) X (Weight of D box)

*Round Down Lower limit and Round up upper limit

Analyze

Theoretical weight range Shipped weights

Compare

48 - 51 45, 50, 50, 50, 51, 52, 60

53% of all data fits within theoretical ranges

Improve

Using▪ No of Bulletins▪ No of Sheets▪ Weight of each

sheet▪ Box weights

Using▪ Calculated

weight▪ SPC Charts

Using▪ Calculated

range ▪ Shipped weight▪ Minitab & Excel

CALCULATE WEIGHT ADD RANGE COMPARE

Target Weight = (Weight per sheet*No. Of sheets) + Weight of the boxes

● Number of sheets = (No. of printed sides per bulletin) X (Total bulletin quantity)

Improve CALCULATE WEIGHT

No. of sides

11X17 4

11X22 5

11X25.5 6

Weight per sheet

Regular Gloss

0.0051795 lb 0.006944 lb.

Box Weight

AA 0.40 lb.

B 0.50 lb.

C 1.05 lb.

D 1.40 lb.

Improve

Control Charts in Minitab

▪ Mean

▪ UCL

▪ LCL

▪ Control charts

▪ Outliers

SPC method in Excel

▪ Mean

▪ UCL

▪ LCL

▪ Control charts

▪ Equations for 95% accuracy

CONTROL CHART - Minitab

CONTROL CHART - Excel

Formula SPC - Excel

SPC Range Given Data

44.5 - 58 45, 50, 50, 50, 51, 52, 60

*Equation calculates for 95%

accuracy

● Set mean and control limits for multiple ranges of

bulletin quantities

● Define how control limits change based on paper type,

number of boxes

● Enable LPi to check box weights against given upper and

lower control limits to ensure 95% accuracy or more

Control

▪ Inkjet printed exact number; offset was manually controlled by operator

▪ Data outliers▫ Reshipments▫ Shipments to two or more locations

Challenges

THANKS!

Any questions?