Skip to main content

A Case Study of Coffee Sachets Production Defect Analysis Using Pareto Analysis, P-Control Chart and Ishikawa Diagram

  • Conference paper
  • First Online:
Intelligent Manufacturing and Mechatronics

Abstract

Nowadays, food and beverages companies in Malaysia are struggle to survive with their rival, hence improving quality and increase productivity are vital. This paper propose the method of analysis a coffee sachet production defectives by using statistical process control (SPC) tools and also to identify each types of defects with their root cause. This paper are using methodology of physical observation through examination of automated production flow line, then Ishikawa cause-and-effect diagram are created. The company valid information are obtained from the professional such as production managers, quality control executives and line supervisors, also staffs and operators that direct or indirectly involves the production line activities through interview and distributed feedback form. After that, a Pareto diagram analysis is done hence creating a control chart (p-chart) to illustrate the result analysis. The result shows there are high number of product defectives according to each type and waste production occur. The problem found was underweight, leaking, overweight, empty, unsealed and height out of the standard. The major causes of defectives coffee sachet and root causes of each defect types are specified which are human, machine, work methods, and materials. While the main root cause of underweight and leaking defect are caused by unskilled worker and improper adjustment at the machine each time before running the production.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 169.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 219.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  1. Chan Sin T, Usubamatov R, Fairuz MA, Amin Hamzas MFBM, Kin Wai L (2014) Engineering mathematical analysis method for productivity rate in linear arrangement serial structure automated flow assembly line. Math Probl Eng 2015:1–10

    Google Scholar 

  2. Sin TC, Usubamatov R, Hamzas MFBMA, Wai LK, Yao TK, Bahari MS (2014) Parameters investigation of mathematical model of productivity for automated line with availability by DMAIC methodology. J Appl Math 2014:1–7

    Article  Google Scholar 

  3. Illa IN, Sin TC, Fathullah GM, Rosmaini A (2018) Mathematical modeling of quality and productivity in industries: a review. American Institute of Physics

    Google Scholar 

  4. Ben-Daya M, Rahim MA (2000) Effect of maintenance on the economic design of x̄-control chart. Eur J Oper Res 120(1):131–143

    Article  Google Scholar 

  5. Hieu HT, Chou TY, Fang YM, Hoang TV (2018) Statistical process control methods for detecting outliers in GPS time series data. Int Refereed J Eng Sci 7(5):8–15

    Google Scholar 

  6. Cesar F, Fernandes F, Filho MG, Bonney M (2009) A proposal for integrating production control and quality control. Ind Manage Data Syst 109(5):683–707

    Article  Google Scholar 

  7. Fouad RH, Mukattash A (2010) Statistical process control tools: a practical guide for Jordanian. JjMIE 4(6):693–700

    Google Scholar 

  8. Zasadzień M (2014) Management systems in production engineering using the pareto diagram and FMEA (failure mode and effects analysis) to identify key defects in a product

    Google Scholar 

  9. Rantama J, Tiainen E, Ka T (2013) A case of implementing SPC in a pulp mill. Int J Lean Six Sigma 4(3):321–337

    Article  Google Scholar 

  10. Taylor P, Benton WC (2007) Statistical process control and the Taguchimethod : a comparative evaluation (October 2014) 29(9):37–41

    Google Scholar 

  11. Gerard K, et al (2008) The use of automated optical testing (AOT) in statistical process control (SPC) for printed circuit board (PCB) production

    Google Scholar 

  12. Mengesha Awaj Y, Singh AP, Yimer Amedie W (2013) Quality improvement using statistical process control tools in glass bottles manufacturing company. Int J Qual Res 7(October 012):107–126

    Google Scholar 

  13. Usubamatov R, Tan CS (2015) Mathematical models for productivity rate of automated lines with reliability attributes of mechanisms. Appl Mech Mater 695(September 2014):521–525

    Google Scholar 

Download references

Acknowledgements

The author would like to acknowledge the support from Universiti Malaysia Perlis (UniMAP) and the fundamental research Grant Scheme (FRGS) under a grant number FRGS/1/2019/TK03/UNIMAP/02/7 from the Ministry of Higher Education Malaysia.

Author information

Authors and Affiliations

Authors

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2021 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Idris, N.I., Sin, T.C., Ibrahim, S., FadzliRamli, M., Ahmad, R. (2021). A Case Study of Coffee Sachets Production Defect Analysis Using Pareto Analysis, P-Control Chart and Ishikawa Diagram. In: Bahari, M.S., Harun, A., Zainal Abidin, Z., Hamidon, R., Zakaria, S. (eds) Intelligent Manufacturing and Mechatronics. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-16-0866-7_115

Download citation

Publish with us

Policies and ethics