Assignment

A manager of a famous coffee shop has realized a reduction in the number of customers for breakfast. Toast bread was served and was a popular menu among customers. Based on observation, during the breakfast most of the customer refuses to eat the toasts bread since last two month (MarchApril 2020). This situation has resulted in 50% increase in the cost of toasts due to rejections and damaging the reputation of the coffee shop. To overcome the problem, the manager has collected several information. He has decided to use several appropriate quality tools to assist him in managing the problem based on some data analysis. A staff has explained to him about the process of making the toast bread such that:

Prepare bread - Plug in toaster Set Parameters Insert Bread Depress Lever Wait until pops up Inspect Serve bread.

In his investigation, the quality group has identified to use scale level from 1 to 9 as specification for the toasts quality checking. Toast with scale 5 is the target level and the toast is considered defective if the score is below 5. Three general factors were believed to impact toast quality including the material, method, man and machine. The manager also wish to identify what are the root causes of the problem.

Data were collected with respect to the following parameters: Age of the bread (in minutes) before serving under factor material, toaster time setting and toaster temperature setting under method (man), thermostat failure and heating element failure under factor machine.

Weekly Net Profit: March April 2020

Week	1	2	3	4	5	6	7	8	9
Net profit (RM)	200	190	210	220	189	178	165	170	150

Defective toast operation data

Causes of Defective Toast	Total Defective Bread
Wrong temperature setting	9
Wrong Time Setting	36
Age Hours Bread (before serving)	14
Heating element failure	8
Thermostat failure	17

Data on 15 sample of breads:

Age (minutes)	Time setting (minute)	Toast Quality
5	2	5
10	3	4
15	4	3
30	1	6
50	0.5	8
25	3	4
10	3.5	4
5	2.5	5
35	1.5	6
40	0.5	7
30	1.5	6
60	0.3	9
45	3	6
3	2.5	5
18	2	4
3	3	5
20	2.5	6

Questions

a) Based on the recorded data and the above given information, apply several appropriate Quality Control (QC) tools.

b) Provide your suggestion and solution to the manager for improvement.