Case Study #2: Deriving Insight Enhancing Operational Efficiency through Targeted Training and Workflow Optimization Objective: This case study focuses on addressing the root cause of high inspection times in a manufacturing company, specifically honing in on the metric of "Time taken for inspection per component" under the broader category of Worker Performance. The objective is to delve into the underlying issues affecting efficiency and propose strategic interventions for improvement. Data: The data here is Generated by an DataGenerator for analysis. I have Analysed 5 situations and reported how the efficiency and the training gap of the workers can be improved for better results and very less errors.

1. Case Study 2:
Knowledge Creation
2023
CREATED BY:
MIGNESH RAJESH BIRDI (8884377)

2. PART 1: ROOT CAUSE ANALYSIS
Metric Selection:
For this example, let's focus on Metric 1: Worker Performance, specifically the parameter of
Efficiency: Time taken for inspection per component. This metric is critical for assessing the
operational efficiency of individual workers.
The 5-Whys Process:
1. Why is the Time Taken for Inspection per Component high?
Answer: The time is high because workers often encounter difficulties in identifying and
recording defects accurately.
2. Why do workers struggle with identifying and recording defects accurately?
Answer: Workers may not have received sufficient training on recognizing all types of
defects or using the tablet system effectively.
3. Why haven't workers received sufficient training?
Answer: The training and certification records show that there's a gap in the training
programs, with some workers missing certain modules.
4. Why is there a gap in the training programs?
Answer: The workforce scheduling data indicates that some workers are not consistently
available during the scheduled training sessions due to irregular work hours.
5. Why do some workers have irregular work hours?
Answer: The workforce scheduling data further reveals that irregular work hours are a result
of inefficient workforce scheduling, leading to staffing issues and inconsistent availability.
Documenting the Progression:
The documentation will include detailed explanations for each "Why?" question, illustrating
the logical progression from the initial metric to the underlying issues. It would emphasize
how each layer of questioning unveils more about the root causes affecting the efficiency of
the inspection process.

3. Insight Generation:
The insight gained through this analysis is that improving workforce scheduling and ensuring
consistent training opportunities can address the root cause of high inspection times. This
insight directly aligns with the overarching goal of enhancing internal operational efficiency
at LPQA.
Part 2: BUSINESS IMPACT ANALYSIS
Benchmark Metric Visual:
Metric: Time taken for inspection per component
Visualization: Bar chart showing the average time taken per component for all workers.
Annotation: This bar chart serves as our starting point, representing the baseline metric for
internal operational efficiency. It allows the Operations Manager to quickly grasp the overall
efficiency of the inspection process.
The initial bar chart serves as a foundational element, providing a clear snapshot of the
baseline metric for internal operational efficiency. This chart meticulously depicts the
performance of workers in terms of components inspected and the time taken for
inspection. By visually comparing the number of components inspected and the
corresponding time invested, the Operations Manager can swiftly gauge the overall
efficiency of the inspection process. The length of each bar directly correlates to the
quantity of components inspected, offering a quick and intuitive understanding of the
workforce's productivity. Simultaneously, the time taken for inspection is represented on
the same chart, enabling a direct comparison between output and the corresponding
time investment. This foundational visualization establishes the groundwork for
subsequent insights, allowing the Operations Manager to identify patterns,
discrepancies, or areas of improvement in the initial assessment of operational efficiency

4. Visualization for the First "Why":
Insight from First "Why": Workers struggle with identifying and recording defects accurately.
Visualization: Pie chart illustrating the distribution of time spent on inspection vs. time
spent on defect identification.
Annotation: This pie chart breaks down the inspection time that’s written in the box with
the yes and no, highlighting the portion dedicated to defect identification in blue and orange
colour. It emphasizes the need to address challenges in defect identification, revealing a
critical aspect affecting efficiency.
The pie chart presented in the first visualization delves into the intricacies of the inspection
process, particularly focusing on the time allocation between overall inspection and the
critical task of defect identification. The chart elegantly divides the inspection time into
distinct segments, vividly represented in blue and orange colors.
The blue portion signifies the time spent on defect identification, while the orange portion
encapsulates the remaining inspection activities. This visual breakdown offers a compelling
insight into the challenges faced by workers, emphasizing the struggle in accurately
identifying and recording defects.
The dominance of the orange segment suggests a potential inefficiency in defect
identification, drawing attention to a crucial aspect affecting overall operational efficiency.
By bringing attention to this specific issue, the pie chart sets the stage for targeted
interventions to streamline defect identification processes, ultimately contributing to
improved overall performance in the inspection workflow.
No
63%
Yes
37%
Sum of InspectionTime vs Time spent on Defect
No
Yes

5.  Visualization for the Second "Why":
Insight from Second "Why": Workers may not have received sufficient training on defect
recognition.
Visualization: Heatmap indicating the training coverage for defect recognition across
workers.
Annotation: The heatmap visualizes the gaps in training, showing areas where workers have
not received sufficient training. This adds a layer to the narrative, emphasizing the
importance of targeted training to improve defect recognition.
To address the identified gaps in training, it's crucial to implement targeted strategies aimed
at enhancing the overall training program:
Firstly, conducting a thorough training needs analysis will help identify specific skill gaps and
knowledge deficiencies among workers. This analysis will enable us to tailor training content
to address the areas where workers have shown incomplete training. Additionally,
implementing a mentorship or peer-assisted learning program can provide valuable support
to workers who may struggle with certain training modules. Regular assessments and
quizzes can be incorporated to ensure ongoing engagement and understanding.
Furthermore, enhancing the accessibility of training materials through digital platforms or
mobile applications can accommodate different learning styles and schedules. Continuous
feedback loops, including surveys and discussions with workers, will be instrumental in
assessing the effectiveness of the training program and making necessary adjustments
TrainingCoverage DefectRecognitionScore WorkerName
61 87 Iona Smith
15 94 Macaulay Branch
45 99 Owen Erickson
9 38 Kirby Beck
54 60 Sacha Patel
6 46 Amal Church
73 11 Stone Rojas
55 11 Jakeem Vega
55 47 Hanna Whitaker
38 25 Morgan Spears
88 99 Donna Miranda
73 60 Lyle Hart
19 3 Ivan Oneal
61 7 Hashim Valentine
24 71 Jada Santiago
19 81 Vivien Pacheco
66 43 Zenaida Huff
82 11 Levi Herman
27 34 Jameson Espinoza
12 11 Uta Whitaker

6.  Visualization for the Third "Why":
Insight from Third "Why": Training programs have gaps, with some workers missing certain
modules.
Visualization: Stacked bar chart comparing completion rates of different training modules.
Annotation: The stacked bar chart illustrates completion rates, emphasizing modules where
gaps exist. It aids in pinpointing specific training areas that need improvement, building on
the understanding of training deficiencies.
By this chart we can conclude which worker has got good amount of training in which
module and can manage to focus on the one which is needed to be improved for overall
efficiency.
We can clearly clarify from it that only 5 of the workers are seen having good statistics on
this bar chart making them the top five and for the rest most of them are in the middle stage
where improvement can be made for accurate results.
0
50
100
150
200
250
300
350
Chart Title
Module1Completion Module2Completion Module3Completion Module4Completion

7.  Visualization for the Fourth "Why":
Insight from Fourth "Why": Irregular work hours result from inefficient workforce
scheduling.
Visualization: Line chart showing the correlation between irregular work hours and
inspection time between 15 workers.
Annotation: The line chart visually connects irregular work hours with inspection time,
highlighting the impact of scheduling on efficiency. It emphasizes the need for improved
scheduling practices.
The line chart presented in the fourth visualization draws a compelling correlation between
irregular work hours and inspection time across a spectrum of 15 workers.
This visual representation illuminates the impact of inefficient workforce scheduling on
overall operational efficiency. The x-axis of the line chart tracks the individual workers, while
the y-axis reflects the corresponding inspection time.
As the lines fluctuate, they vividly showcase the irregularities in work hours and their direct
influence on the time dedicated to the inspection process. The upward spikes or dips in the
lines indicate periods of irregular work hours, which directly translate into variations in
inspection time. This visual narrative effectively underscores the critical role that scheduling
inefficiencies play in disrupting the operational workflow.
By visually connecting irregular work hours with inspection time, the line chart emphasizes
the pressing need for strategic improvements in workforce scheduling practices to optimize
efficiency within the inspection process
0
10
20
30
40
50
60
70
CHART TITLE
InspectionTime IrregularHours

8.  Visualization for the Fifth "Why":
Insight from Fifth "Why": Inefficient workforce scheduling is due to staffing issues and
inconsistent availability.
Visualization: Area chart displaying the fluctuation in worker availability over time.
Annotation: The area chart provides a holistic view of worker availability issues, showcasing
periods of understaffing or overstaffing. It ties together the entire narrative, emphasizing the
root cause of inefficient scheduling.
The visualization for the fifth 'Why' takes the form of an area chart that skillfully
encapsulates the fluctuation in worker availability over time.
The x-axis of the chart denotes the temporal dimension, allowing a chronological
assessment, while the y-axis represents the varying levels of worker availability. The shaded
areas in the chart dynamically portray periods of both understaffing and overstaffing,
providing a comprehensive and holistic view of the workforce scheduling challenges.
The upward and downward curves in the chart effectively showcase the ebb and flow of
worker availability, exposing the root causes of inefficient scheduling. This visualization
serves as a pivotal element in tying together the entire narrative, highlighting the intricate
relationship between staffing issues, inconsistent availability, and the resultant disruptions in
workforce scheduling.
It serves as a visual anchor, emphasizing the necessity for strategic interventions to address
the core issues and optimize workforce scheduling practices for enhanced operational
efficiency.
0
10
20
30
40
50
60
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Chart Title
AvailableWorkers ScheduledWorkers StaffingIssues

9. Annotation and Rationale:
Annotations: Each visual is accompanied by detailed annotations explaining the rationale
behind the choice of visuals, how they complement the narrative, and the specific insights
they provide.
Rationale: The annotations guide the Operations Manager through the thought process,
clarifying the significance of each visual element in the overall analysis. They highlight
actionable insights and areas for improvement.
This non-functional dashboard mockup aims to visually guide the Operations Manager
through the progression from the baseline metric to meaningful insights, fostering a deeper
understanding of the root causes affecting internal operational efficiency.