1. Weight Tolerances
Continuous Improvement
Project

2. Liturgical
Publications Inc.
Because Vibrant Churches Matter
INTRODUCTION

3. TEAM
Project Owner: Jeanne Krien
Manager: Ken Pranger
Project Sponsor: Tracey Rogers
Advisor: Prof. Alireza Kabirian
Team: Anuj Bindagi
Bhanu Poreddy
Joanna Rumbley

4. PROFILE
Product: Church Bulletins
Accounts: Approximately 800
Volume: Customer order (Varies)
Time: Weekly

5. Current Issue
● Wrong shipment to wrong
account
● Less or more quantity than
ordered
PROBLEM

6. GOAL
To Establish Acceptable Range of
Weights for Shipped Packages by
Account

7. Our Approach
04 Improve
01 Define
02 Measure
03 Analyze
05 Control

8. 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

9. Define
SHIPPED WEIGHT
▪ Checked at shipping
COMPARE
THEORETICAL WEIGHT RANGE
▪ Formula based calculation

10. 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

11. 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

12. 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

13. Analyze

14. Analyze

15. Analyze

16. 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

17. Analyze
Theoretical weight range Shipped weights
Compare
48 - 51 45, 50, 50, 50, 51, 52, 60
53% of all data fits within theoretical ranges

18. 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

19. 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.

20. Improve
Control Charts in Minitab
▪ Mean
▪ UCL
▪ LCL
▪ Control charts
▪ Outliers
SPC method in Excel
▪ Mean
▪ UCL
▪ LCL
▪ Control charts

21. CONTROL CHART - Minitab

22. CONTROL CHART - Excel

23. Formula SPC - Excel
SPC Range Given Data
44.5 - 58 45, 50, 50, 50, 51,
52, 60
*Equation calculates for 95%
accuracy

24. ● 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

25. ▪ Inkjet printed exact number; offset was
manually controlled by operator
▪ Data outliers
▫ Reshipments
▫ Shipments to two or more locations
Challenges

26. THANKS!
Any questions?