Quality Planning and Analysis for Solar Roof Tiles - XYZ Company

The XYZ Company plans to launch its own brand of solar tiles to compete in the new age market of renewable energy sources. The entire project is based on three product lines which will be initially launched. Among the three lines, Grey roof tiles will be launched first. The company has done extensive market survey to make the product lines successful and followed ISO 9001:2015 for the purpose. The description of the entire survey and planning of the company has been provided in this report.

UTS: ENGINEERING
Assignment Cover Sheet
STANDARD Mode
SUBJECT: Quality Planning and Analysis
SUBJECT NUMBER:
ASSIGNMENT NUMBER:
STUDENT LAST NAME:
STUDENT FIRST NAME:
STUDENT ID:
1

Assignment # 1
“Quality Planning and Analysis”
Solar Roof Tiles
DEVELOPMENTCOMPANY – XYZ
2

1.0 Executive Summary
The XYZ Company plans to launch its own brand of solar tiles to compete
in the new age market of renewable energy sources. The entire project is
based on three product lines which will be initially launched. Among the
three lines, Grey roof tiles will be launched first. The company has done
extensive market survey to make the product lines successful and followed
ISO 9001:2015 for the purpose. The description of the entire survey and
planning of the company has been provided in this report.
3

Table of Contents
UTS: ENGINEERING......................................................................................................................................1
Assignment Cover Sheet..............................................................................................................................1
STANDARD Mode........................................................................................................................................1
1.0 Executive Summary.........................................................................................................................3
2.0 Introduction...........................................................................................................................................6
3.0 Customer Satisfaction.......................................................................................................................7
3.1 Stake Holder Analysis....................................................................................................................7
3.2 Capturing Customer Needs................................................................................................................9
3.2.1Customer Interviews................................................................................................................9
3.2.2 Focus Group..........................................................................................................................10
3.2.3 Customer Surveys................................................................................................................10
3.2.4 Customer Visits.....................................................................................................................11
3.2.5 Customer Complaints...........................................................................................................11
3.3 Customer needs analysis (KANO Analysis).............................................................................11
4.0 Design Requirements...........................................................................................................................16
4.1Translating Customer Needs into Design Requirements (QFD)........................................................16
4.2 Design Risk Analysis (FMEA)............................................................................................................18
5.0 Selection and Evaluation of Suppliers.................................................................................................19
5.1 Component Identification................................................................................................................19
5.2 Criteria for Supplier Selection.....................................................................................................20
5.3 Constructing a Supplier selection system.................................................................................21
5.4 Conclusion.......................................................................................................................................22
6.0 Statistical Process Control..............................................................................................................22
6.1 Identifying the Process................................................................................................................22
6.1.1 Design.....................................................................................................................................23
6.1.2 Supplier Selection.................................................................................................................23
6.1.3 Development of subcomponents........................................................................................23
6.1.4 Subcomponent inspection....................................................................................................24
6.1.5 Prototypes..............................................................................................................................24
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6.1.6 Logistics and Inventory.........................................................................................................24
6.1.7 Packaging..............................................................................................................................24
6.1.8 Distribution.............................................................................................................................24
6.2 SPC chart to monitor process.....................................................................................................25
6.3 Constructing and Using a SPC chart.........................................................................................26
6.4 Interpretation..................................................................................................................................28
7.0 Problem Solving...............................................................................................................................29
7.1 Identifying the problems..............................................................................................................29
7.2 Brainstorming................................................................................................................................30
7.3 Why-Why Analysis...........................................................................................................................31
7.4 Cause and Effect Diagram..........................................................................................................32
7.5 Pareto Analysis.............................................................................................................................32
8.0 Conclusion...........................................................................................................................................34
9.0 Reference:...........................................................................................................................................35
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2.0 Introduction
With the consumption of non-sustainable power sources, for example,
petroleum products, and world is moving towards sustainable power
source. One of the solid sustainable power sources is Photovoltaic cell,
otherwise called sun oriented cell. The request of the sunlight based cell is
expanding step by step on business and residential levels. Analysts are
attempting to make it more productive. One of the worries of numerous
shoppers is that putting sun based boards on the rooftop slaughters the
outline feel of the house. Numerous organizations are making sun powered
boards however XYZ has outlined an exceptional item, named as Grey
Roof product line. These Grey Roofs are made of the architectural roof
which looks conventional from the separation; however they will have the
capacity to produce power from sun. This Grey Roof X15-BR75 series
offers the vitality arrangement which is known as building-incorporated
photovoltaic material. An architectural roof is outlined tastefully to expand
the looks of the house. An architectural roof is sufficiently solid to withstand
any effect that nature can toss on them (Bunthof et al., 2017).
The Grey Roof offers the vitality arrangement with sturdy Grey Roof, while
keeping up tasteful looks of the house. To store vitality created from these
rooftops, XYZ offers Grey glass panels of 60x82 cm and can resist 8 cm of
hailstones. Installation does not require any adhesive material, but fixing
technique makes the structural robust and tough for almost 30 years.
Larger roofs can be covered due to smaller panels and the entire panel can
be disassembled easily (Dijk et al., 2017).
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The Grey Roof offer tasteful looks however this outline may decrease the
proficiency of the architectural roof. Presently a procedure for the new Grey
Roof architectural roof advancement and utilization of value instruments by
XYZ. The toughest structure with competitive pricing makes the Australian
company a tough competitor in the market.
3.0 Customer Satisfaction
3.1 Stake Holder Analysis
XYZ is an eminent Australian company producing top quality solar panels,
used as a sustainable alternative in building integration (Prell, Hubacek &
Reed, 2009). In the year 2017, XYZ Grey roof is nominated for Australian
design award. It is an organization providing the Grey Roof architectural
roof to the purchasers, and having a strong research and development
team, XYZ remains a market leader in area of building assimilation of PV
technology. Due to worldwide popularity and market share in solar roof
modeling, a partner investigation is done to comprehend the client needs
and to cook these requirements productively (Jepsen & Eskerod, 2009).
Table 1: Stake Holder Analysis information
Stakeholders Requirements
Internal
Direct Customers
Item with most recent innovation meeting all execution
desires.
Solid item offering toughness and usefulness
Long guarantee and great client bolster
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Most extreme incentive for cash
Distributors
In time conveyance of requests
After deals bolster After sales support
Contractors
Business development with steadiness
Consistent demand
Support for the advancement of new item and the setting up
an assembling unit for another item improvement.
Challengers
Sharing of information and innovation to upgrade
productivity
Joint dares to investigate the new business zones
Higher Administration
Commitment in the development of the association to
expand the brand esteem
Better notoriety in showcase for solid items
Shareholder
Great profit for their speculations
Standard reports on business procedures and advance of the
organization.
Production Teams
Safety and Wellbeing of laborers
Great compensations with work-life adjust
Reasonable courses of events
Best in class apparatus for creation
8

Promotion Team
Increment mark an incentive through powerful showcasing
Bring issues to light for the sustainable power source
External
Government
Assessment installments on time and money related reviews
Consistence to the controls and laws
Utilization of non poisonous materials underway.
Least natural effect
Conservationist and the
general public
Production using non toxic materials.
Bare minimum ecological impact
3.2 Customer Needs Capturing
The clients' desires and prerequisites can be classified utilizing Voice of the
Customer strategy to acquire the in-depth knowledge of customer
anticipation. Information can be procured through various strategies,
subsequent do the five techniques comprehend the voice of the clients.
ISO 9001 standard is followed for the analysis; customer quality
requirement meet and increasing customer satisfaction through
enhancement of performance and regulation are guaranteed (Hoyle, 2017).
3.2.1Customer Interviews
In this technique organization delegates meet the potential clients for their
desires and necessities. These meetings offer a financially savvy strategy
to assemble information and assess the inclinations of the organization.
The meeting for the most part comprises of the logical inquiries which are
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intended to get the coveted data. These meetings are useful to get criticism
from the clients. The information acquired from these meetings for the most
part is broad and does not really center on the plan. In interviews clients
tend to give input from their own particular recognition. Thus a ton of info is
assembled from this common talk between two gatherings. Guidelines are
taken from 2015 standard of ISO 9001 and emphasis is given on extensive
continuous transformation of customer handling process based on
customer requirements (Kim, Hong & Magerko, 2010).
3.2.2 Focus Group
Center gathering can be included the past clients, administrators or the
workers of the organization. The members sit together and have talk on the
need and their desires. Center gathering pioneer can give the members
open finished inquiries. The information accumulated from this strategy is
subjective (Reed et al., 2009). Center gathering gatherings bring about
more extensive information, since members are urged to talk about their
discernment on a particular necessity.
3.2.3 Customer Surveys
Client studies are practical technique to decide the client needs and
desires. It is an essential device in statistical surveying. In this strategy an
arrangement of inquiries are displayed before a client. The input is more
often than not as far as evaluations. These evaluations give the
unmistakable picture of what are the client’s musts, needs and additional
items includes in item. These review polls require incredible accentuation
on the nature of the inquiries, since clients can't give reply outside the
evaluations.
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3.2.4 Customer Visits
Client visits are like above techniques as far as data accumulation. The
philosophy incorporates giving a client organized discussion, while a
delegate of organization in going to a client or the other way around. This
philosophy is very subject to the decision of the client. Information can be
affected by the individual view of the client decided for the visit.
3.2.5 Customer Complaints
Client grumbling is a viable technique to examine the client's needs. For
this reason information from the past and current clients is investigated.
Concentrate the client protestations is basic to enhance the procedure and
maintain a strategic distance from botches in the new item advancement.
3.3 Customer needs analysis (KANO Analysis)
XYZ utilized progressed KANO demonstrate type 4 to comprehend the
client requirements for Grey Roof architectural roof. Clients are given
surveys in two configurations that are functional and dysfunctional. They
are offered alternative to react in appraisals as underneath.
Table 2: KANO Analysis Questionnaire
Question Rating
Functional In the event that the Grey Roof conveys high
proficiency without executing style of house.
1 It will be decent to
have this
2 It is my fundamental
necessity
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3 Nonpartisan
assessment
4 Satisfactory
5 Exceptionally
Displeased
Dysfunctiona
l
In the event that Grey Roof doesn't give great
proficiency and is massive in estimate
1 It will be decent to
have this
2 It is my fundamental
necessity
3 Nonpartisan
assessment
4 Satisfactory
5 Exceptionally
Displeased
Despite the fact that client reactions are taken in five rating grades, yet
here only three of them have been considered (Chen et al., 2010). The
three grades are as follows,
Must (M)
Need (W)
Attractive (E)
Q, I: For these situations evaluations are disregarded
Table 3: Customer Requirement Generation
Customer
Requirement
Dysfunctional
Functional 1 2 3 4 5
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1 Q E E E W
2 R I I I M
3 R I I I M
4 R I I I M
5 R R R R Q
These evaluations has been allotted in the wake of being searching for
various characteristic the utilized numerical arrangement for Kano
investigation KR is as beneath:
Table 4: Requirement base Arrangement
REQUIREMENTS
E W M I R FACTOR
MULTIPLIED
SUM (P)
SUM OF
RESPONSES KR
3 2 1 0 -2
1
Convey Sufficient
effectiveness at every
working environment
0 0 20 0 0 20 20 1
2 Capacity to keep away
from over warming 0 2 18 0 0 22 20 1.1
3 Least requirement to
clean
0 1 19 0 0 21 20 1.05
4 Most extreme
proficiency
1 2 17 0 0 24 20 1.2
5 Off network capacity 0 2 18 0 0 22 20 1.1
6 Capacity to endure clean 1 1 18 0 0 23 20 1.15
7 Realistic Cost 0 1 16 2 0 18 19 368
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8 Reasonable adjustment 0 0 20 0 0 20 20 1
9 Simple to introduce
devoid of altering
engineering of house
0 0 20 0 0 20 20 1
10 Capacity to survive
nature 0 1 19 0 0 21 20 1.05
11 Minimum maintenance 2 16 1 1 0 39 20 1.95
12 Insulating 2 17 1 0 0 41 20 2.05
13
Capacity to create power
below meager
circumstances
2 16 1 1 0 39 20 1.95
14 Versatile plan for future
changes 3 17 0 0 0 43 20 2.15
15
Clear thought of
conjecture age before
establishment
1 18 1 0 0 40 20 2
16 Simple to clean 0 19 1 0 0 39 20 1.95
17 Low odds of rupture 1 18 1 0 0 40 20 2
18 Compaction 3 15 1 1 0 40 20 2
19 Anti heat property 5 12 2 1 0 41 20 2.05
20 Divider based regulator 7 9 4 0 0 43 20 2.15
21
Utilization of solid yet
lovely substance to
supplant aged boards
18 2 0 0 0 58 20 2.9
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From the KANO analysis customer requirements are categorized and
needs are structured by estimation of KR as below.
In the event that KR is 0.5, it is an absolute necessity.
In the event that KR is equivalent to 1, it is a need.
In the event that KR is equivalent to 2, it is considered as attractive.
Utilizing above properties, the client require examination is as take after
(Xu et al., 2009).
Table 5: KANO analysis Categorized
Musts Wants Extras
1
Convey abundant
proficiency at every
working environment
Capability to endure
nature
Use of strong yet
beautiful material to
replace old panels
2 Capacity to stay away
from over warming Bare minimum repairs Wall hanging regulator
3 Least requirement to
clean Fire Resistance Protection from high
temperature
4 Off framework capacity
Capability to produce
electricity in adverse
circumstances
5 Capacity to endure tidy Adjustable design for
prospect development
6 Realistic Cost
Apparent plan of
estimate making ahead of
fitting
7
Simple to introduce with
no shifting engineering of
residence Simple to clean
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8
Simple to introduce with
no shifting engineering of
house
Little probability of
rupture
4.0 Requirements for Design
4.1 Design Requirements from Customer Needs (QFD)
The consumer necessities are translated into scoring figures in accordance
with the design necessities for the rationale of quality operation purposes
(Tayal, 2013).
Customer
Needs/
Expectations
Significance
Tile
Dimension
Tile Placement
Tile Material
Power
Generation
Silicon Layer
Tile Placement
Battery
Placement of
Tile
Safety Switch
Serviceability
Convey
abundant
proficiency at
all working
conditions
9.
8 9 9 3 3 9 1
Capacity to
maintain a
strategic
distance from
over warming
9 9 1 3 9 1 9 3
Least Need to
clean 8.
8 9 3 9 3 9
Off lattice
ability 7.
5 9 9 9
Capacity to
endure clean 7 9 9
Sensible cost 8 8 9
Simple to 7 9 3 3 3
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introduce with
no altering
design of
residence
Capacity to
endure nature 9.
5 9 9 9
Least upkeep 9.
5 9 9 9 9
Insulating 9 3 9 9
Capacity to
create power
in adverse
circumstances
5 9 9 9 3
Versatile plan
for future
enhancements 6 9
Comprehensibl
e thought of
conjecture age
ahead of
establishment
5.
5 9
Simple to
clean 5 9 9
Little odds of
crack 5 9
Utilization of
solid yet lovely
stuff to
supplant older
boards
4.
5 3 9 9
Divider holding
regulator 4 9 9
Heat defiant 4 3 3 9 1
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Total
Attainment
426.9
371.7
247.5
452.9
489.3
91.2
392.1
222.8
222.8
403
4.2 Design Risk Analysis (FMEA)
Step by step failure mode analysis is done on zenith performers by
considering all probable failures in the XYZ Roof design. The effect
analysis has been provided in the following chart.
Table 6: Failure Model and effect analysis
Component or
function
Possible
Letdown Effect Cause of
failure
Risk
before
action
adopted
Action taken
to reduce risk
Risk after
action
taken
P S R P S R
Tile
measurement
Ill-advised
fitting
Decreased
effectiveness
Inappropriate
cutting
3 4 12
Right material
to interlock
structural
rooftop
1 4 4
Tile Rupturing Close down Improper 4 3 12 Investigation 1 3 3
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Substance of
framework
material
choice
of tiles prior
to
establishment
Energy
Production
Low power More
reliance on
control
matrix
Improper
edge to sun
3 5 15
Most extreme
contact of
sun light 1 3 3
Tile position Rupture of
Grey tiles/
diminish
effectiveness
Framework
collapse
Inappropriate
Installation
5 3 15
Utilization of
high-quality
stuff 2 5 10
Security
Button
Automatic
circuit break
Fire Power
breakdown 3 3 9
Appropriate
checking of
switches 2 3 3
5.0 Selection and Evaluation of Suppliers
5.1 Component Identification
Grey Roof framework contains number segments and requires various
providers. A portion of the segments that ought to be outsourced are
considered by the company as below,
1. Wiring of architectural roof
2. Technology to settle the architectural roof
3. Safety valve
4. Home Grid framework
5. Power controller
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5.2 Criteria for Supplier Selection
Out of above specified five segments, the control divider is taken into
thought to set up the provider determination criteria.
Power divider is a critical segment in the close planetary system. At the
point when sun is on its pinnacle the sun based boards produce more
power than morning. With a specific end goal to have reliable supply from
the framework, batteries is required which stores vitality amid crest age and
give it use in off pinnacle time (Ho, Xu, & Dey, 2010).
Subsequently beneath is the model to be considered to choose a proper
provider
1. Advance apparatus and plan capacities
2. Combustion safe batteries
3. Efficient recharge time
4. Cabling safe from fire
5. Arrangement to keep away from excess heating
6. High standard material
7. Location and strategic accessibility
8. Ecological factor
9. Precedent execution
10. Structuring with building group notoriety
11. Significance for cash
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5.3 Build a Supplier choice structure
For the chosen part three of the probable providers are thought about.
Providers are specified a ranking by selected standard. What's more,
significance to every part is set and hence weighted score is
determined. Three proposed suppliers were studied here.
Table 7: Supplier selection system
CRITER
IA
SUPPLIERS
PTN1 Energy
score
PTN2 Energy
score
PTN3 Energy
score
Weight
ed
Attainme
nt
Weighte
d
Attainme
nt
Attainme
nt
Weighte
d
Attainme
nt
Attainme
nt
Weighte
d
Attainme
nt
Propel
apparatus
and plan
abilities
9 7 63 8 72 5 45
Heat proof
power cells 8 8 64 8 64 6 48
Ready to
give a
decent
recharge
time
7.5 9 67.5 7 52.5 7 52.5
Flame
resistant
cabling 9 8 72 8 72 8 72
Framework
to maintain
a strategic
distance
from over
warmth
7 9 63 5 35 3 21
Great
quality
8 6 48 7 56 9 72
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material
Area and
calculated
accessibility 8.5 7 59.5 6 51 9 76.5
Natural
feature 6 9 54 8 48 7 42
Past
execution
and the
notoriety of
the
association
7 8 56 7 49 9 63
Outline and
designing
group
notoriety
7 7 49 8 56 8 56
Worth for
Price 6 7 42 6 36 7 42
TOTAL 85 638 78 591.5 78 590
5.4 Conclusion
The above table demonstrates that suppliers PTN2 and PTN3 are
equivalent to much degree for this venture. However, the PTN2 offers co
ordinations and support. Then again the offer focused cost yet the
natural factor and their failure to plan batteries to maintain a strategic
distance from overheat of the framework.
Thus from the previously pointed out table the PTN1 has the pilot score
of 638 and along these lines is the designated provider. Their individual
scores are higher in most of the fields compared to PTN2 and PTN3
energy suppliers.
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6.0 Statistical Process Control
6.1 Identifying the Process
Solar roof panels are the generally utilized item as the alternative to non
sustainable energy sources and therefore there is ample reason no
bargain on the client's end. They request the most ideal accessible item
without any imperfections as this is the exceedingly costly item.
Significant procedures required for conveying to client are as per the
following structure. Grey Roof architectural roof have numerous
mechanisms and fitting together the product possibly will include a lot of
steps which are scheduled underneath.
6.1.1 Selection of Design
The initial footstep is to plan the Grey Roof that resemble the customary
architectural roof yet can create power. The design is to keep away from
the massive sunlight based boards on the rooftop. It additionally
characterizes the different parts and the objective focuses for their
eminence affirmation, and the information from the past knowledge is
basic in the assurance of adequacy of the procedure.
6.1.2 Selection of Supplier
The initial footstep is the ID of the segments that should be brought from
different merchants. Subsequent to the distinguishing proof of provider
board for every part, citation from the diverse provider is taken. Every
provider is assessed for number of various elements and appropriate
seller is chosen (Cederman, Wimmer & Min, 2010).
6.1.3 Development of subcomponents
After the determination of the provider for subcomponents, the
advancement stage starts. Building drawing and configuration is then
23

finished. It is normal as of the provider who will begin construction
process immediately and they will convey the segments ahead of the
packing point in time.
6.1.4 Assessment of Subcomponents
Each and every sub module is inspected in every aspect and every
divergence from the plan is taken into record and verified. Subsequently,
producing process is created and information is stored for future
purpose. Examination and approval of the subparts is likewise produced.
6.1.5 Prototypes
Model is amassed and approval is looked for from the partners. Any
worry with respect to the assembling and any potential dangers are
assessed here and remedial measures are taken if vital. The procedure
likewise includes the improvement of the mechanical production system.
6.1.6 Inventory and Logistics
An essential element in the procedure is the regulation of the resources
engaged with the procedure and stock administration. With the goal that
generation line can run easily. Mechanical production system must be
designed to give ideal space and working
6.1.7 Packaging
The stuffed segments are stacked on the appropriate shipping and are
send out to the end buyers. The time dispersion is essential and stock
management must be kept up to arrange on the off chance that anything
is running low.
6.1.8 Distribution
The stuffed parts are stacked resting on the rational shipping and are
sent out to the end purchasers. The time conveyance is essential and
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stock management must be kept up to arrange on the off chance that
whatever thing is consecutively short.
6.2 Monitoring process with SPC chart
An assembling procedure is mind boggling in nature and regularly it is
mattered to part of varieties additional time. The reason can be whatever
thing from the natural world or the some other uncommon reason. In any
case, it will encompass enormous impact on the notoriety of the
organization if the generation gets deferred for any grounds. In this way
it is critical to screen the procedure. The most ideal path is to dissect the
information assembled from everyday observations. By utilizing
arithmetic, an unpleasant estimation can be drawn. The measurable
information is to be utilized. Control diagrams gives the thorough look of
what can turn out badly in the creation procedure with the goal that
important move can be made to limit the impact of these occasions. The
upper control restrict and the lower control constrain give the estimation
of the adequacy. These are estimated as for a mean esteem.
There are distinctive kinds of SP outlines. The determination of the
graph relies upon what is being investigated for the procedure.
P-Chart
Regularly P outline are utilized to perceive what number of imperfect
items are in an example measure which is variable. Information being
utilized to plot is the information which is assembled from everyday
schedule. The kinds of deformity of the quantity of dismissal per
segment which are happening in the process under talk are not
determined simultaneously. If there should be an occurrence of Grey
25

Roof tile, we can plot p graph utilizing the information of the imperfect
parts in a settled measure of time.
N-P Chart
In the event that the example estimate isn't variable in P-diagram and is
consistent all through the procedure, it will end up being the NP graph.
The graph is valuable since we can perceive what number of flawed
items is in a cluster of a particular example amount. The quantity of
deformities in a particular segment has no part here. As far as possible
these are controlled by the rehashed execution information.
X Chart
It's anything but an extent based graph; rather it is an estimation based
outline. It is best used to examine the procedure which has quantifiable
yield, for instance, stature, length, breadth and so on.
X graphs are utilized for a particular time as it are. In these graphs a
particular measurement is an example at particular time period is plotted
against the time. The relation is then assessed while contrasting them
and the known example of unrestrained process. This is perfect in light
of the fact that the example measure is restricted in this (Montgomery,
Runger & Hubele, 2009).
6.3 Constructing and Using a SPC chart
Let’s take the information gathered on the quantity of dismissal of Grey
Roof for particular time allotment or move in seven days. Here the
example estimate is variable all the while.
No. of rejected architectural roof = x
26

Add up to architectural roof created in a move = n
Proportion of dismissal to generation = p
Normal dismissal per part = bar
Upper Control Limit and Lower Control Limit are three standard
deviations restrict that are computed utilizing the formula for root mean
square deviation. The p diagram will be drawn utilizing P against the
UCL and LCL.
Table 8: Control limits for p-bar chart
SL DAY AND SHIFT
NO OF
REJECTED
ARCHITECTURA
L ROOF
TOTAL
PRODUCTIO
N (N)
P 3*SQRT UCL LCL
1 MONDAY
first half 7 52 0.1346 0.1695 0.3796 0.0407
2 MONDAY
second half 11 48 0.2292 0.1764 0.3866 0.0337
3 MONDAY night 12 37 0.3243 0.2009 0.4111 0.0092
4 TUESDAY
first half 6 58 0.1034 0.1605 0.3706 0.0497
5 TUESDAY
second half 10 60 0.1667 0.1578 0.3679 0.0524
6 WEDNESDAY
first half 14 34 0.4118 0.2096 0.4198 0.0005
7 WEDNESDAY
second half 7 50 0.1400 0.1729 0.3830 0.0373
8 WEDNESDAY
NIGHT 9 32 0.2813 0.2161 0.4262 -
0.0059
9 THURSDAY
first half 6 41 0.1463 0.1909 0.4010 0.0193
10 THURSDAY
second half 11 37 0.2973 0.2009 0.4111 0.0092
11 THURSDAY
NIGHT 9 40 0.2250 0.1933 0.4034 0.0169
12 FRIDAY
first half 10 55 0.1818 0.1648 0.3750 0.0453
13 FRIDAY
second half 8 44 0.1818 0.1843 0.3944 0.0259
14 SATURDAY
first half 9 47 0.1915 0.1783 0.3884 0.0319
27

15 SATURDAY
second half 7 51 0.1373 0.1711 0.3813 0.0390
P-BAR 0.2101
5
MONDAY
first half
MONDAY
second half
MONDAY night
TUESDAY
first half
TUESDAY
second half
WEDNESDAY first half
WEDNESDAY second half
WEDNESDAY NIGHT
THURSDAY
first half
THURSDAY second half-0.1000
0.0000
0.1000
0.2000
0.3000
0.4000
0.5000
P-bar Control Chart
P
UCL
LCL
SHIFTS
Probability Limits
6.4 Elucidation
The layout demonstrates that there is issue just in one move, on
Wednesday the divergence touched the upper control limit. Regardless
of the way that it moved closer yet it didn't outperform, and in remaining
cases a customary lead is shown. Along these lines the method of age
of architectural roof can be considered as a technique in control. In any
case, the true blue conclusion is to lead an examination on Wednesday
proceed onward examination why there are such an expansive number
of expulsion in that move (Fonseca, 2015).
For better perceptive of the daylight based tile age process, we ought to
use N-P graph. Since this P diagram didn't use data of the amount of
deformations happened (Simon et al., 2010).
28

The graph demonstrates that there is issue just in one move, on
Wednesday the divergence touched the upper control restrain. In spite
of the fact that it drew nearer however it didn't surpass, and in rest of
cases a typical conduct is displayed. Henceforth the procedure of
creation of architectural roof can be considered as a procedure in
charge. In any case, the sensible conclusion is to lead an examination
on Wednesday move on examination why there are such a large
number of dismissals in that move.
To have the better comprehension of the sun powered tile creation
process, we should utilize N-P graph. Since this P graph didn't utilize
information of the quantity of imperfections happened.
7.0 Problem Solving
7.1 Identifying the problems
Grey Roof is only a segment of a broad framework and there are various
parts in the framework which can make it breakdown. A portion of them
are
• Poor light assimilation
• Accumulation of earth
• Overheating
• Low productivity because of the material utilized for beautification
To handle this issue in precise approach following apparatuses are
utilized.
29

• Forms for critical thinking
• Process stream diagrams
• Brainstorming
• Diagram of circumstances and end results
• Why-why analysis
• Check sheet
7.2 Brainstorming
Conceptualizing is a procedure which is utilized on the off chance that
when we forward a group of couple of individuals which examines the
conceivable foundations for the issue which is happening and they set forth
the reactions which are recorded due to that talk. Given a chance to take
the case of accumulating the shipping, conceivable causes could be
following,
 Lesser capital sum
 Inadequate specialized personalities
 Inadequate specialized individual
 Un-accessibility of huge spaces
 Restricted in size assembling site
 Un-reasonableness to buy costly hardware's
 Un-accessibility of specialists
These recorded couple of answers for the emerged issue have been
featured which can be a conceivable answer for the happened issue.
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Experts from various utilitarian groups together conceptualized on the
conceivable reasons for disappointments. In these discourses conclusions
are drawn for the most part from the past encounters of the groups in the
comparative procedure. At that point FMEA is led to take note of any new
disappointment and a pathway is intended for what's to come.
Table 9: Reasons for Problems
Concern: No power age from tile
1 Poor presentation to daylight
2 Uncalled for wiring
3 Uncalled for obsession
4 Battery glitch
5 Sun based cell imperfection
7.3 Why-Why Analysis
This is uncommon conceptualizing procedure which revolves around
finding the fundamental driver of the mistake. We have to keep inquisitive
with reference to why question to each reason until the point when the
moment that we locate the insightful arrangement of essential issue. The
strategy is clarified with the case as this is extreme conceptualizing
strategy which center on finding the underlying driver of the
disappointment. We need to continue inquiring as to why question to each
reason until the point that we find the consistent solution of essential issue.
The procedure is expounded with the case as take after (Lee et al., 2009).
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7.4 Cause and Effect Diagram
The cause and effect diagram is also identified as the fish bone diagram, It
includes all the probable causes and assembles the under the predefined
extensive fields of the causes for the problem (Harrington, 2016).
Figure 1: Cause Effect Diagram
7.5 Pareto Analysis
In the present-day world of accumulating due to intensely aggressive
nature of the market, different institutes have started searching for various
methodologies. It also practices to lessen the wastage of crude materials.
Squander minimization assumes vital part in assembling enterprises.
Depletion of crude resources controls cost of the item and reductions the
profit level of the business or on the other way round production. Along
these lines enterprises are constantly attempting to decrease operational
wastage. Pareto investigation serves to recognize diverse deformities and
arrange them as per their noteworthiness. Dismissal of crude materials is
32
Human
Error
Faulty
Design
Staff
Problems
Governence
Problem
Manufacturin
g Obstacles
Technical
Inability
Asset
Loss
Defecti
ve
items
Loss in
Materi
al
Loss
for
Welfar
e
Target
Miss
Advers
e
Market
Overall
Problem
s

prompted by the deformities. To decide believable main drivers of release,
Cause and-Effect Graph (CED) is likewise an extremely supportive
instrument. It distinguishes, sort, and show reasons for a particular issue or
quality trademark. It graphically delineates the connection between a
known result and all the factors that affect the result and consequently to
recognize the believable underlying drivers that is essential explanations
behind a particular impact, issue, or condition. Data is collected on possible
cause, their frequencies are plotted along their accumulated percent
(Ahmed & Ahmad, 2011).
Table 10: Root Cause Analysis
Root causes Occurrenc
e % Cumulative
%
Inappropriate electric
wiring 30 46.15 46.15
Inappropriate direction to
Sun 17 26.15 72.31
Accretion of dust 8 12.31 84.62
Unacceptable low power
cells 5 7.69 92.31
Incorrect positioning of
solar tile 3 4.62 96.92
Zero light contact 1 1.54 98.46
Erroneous substance of
tile 1 1.54 100
Total 65 100
8.0 Conclusion
The market survey and product analysis found that the Grey Roof tile
product line was appropriate for the modern market of solar tiles. Less
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number of competitors was identified as one of the major reason. The
KANO analysis and problem solving methodology inspired the
management to increase its product lines for the market. The other two
parallel products for office purpose and house roof covering was discussed.
The Grey roof product line was well inside the control range and hence
production capacity was also increased for the European and Asian
markets. The profitability analysis was done after the quality analysis.
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