3021 08 Problem Solving Tools

Problem Solving Tools INSY 3021 Auburn University Spring 2008

Exploratory Tools Pareto Analysis  Fish Diagrams  Gantt Chart  PERT Chart  Job / Worksite Analysis Guide 

Pareto Analysis 

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Items identified and ordered on common scale in decreasing frequency, creating a cumulative distribution 80/20 Rule: 20% of the items account for 80% of the problems Allows the company to concentrate resources on the jobs with the most problems

Pareto Analysis 

Example Diagram Figure 2-2

Fish-bone Diagrams Cause-and-effect diagrams  Identified problem or undesirable result is the “head”  Contributing factors are the “bones”  Typical categories include: Human, machine, methods, materials, environment, and administrative  Estimates associated probabilities 

Fish-bone Diagrams 

Example Diagram Figure 2-3

Gantt Chart  

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Used for planning of complex projects Shows expected start and completion times, also duration of events Similarly, major events can be broken into smaller sub-tasks Shade the bars to show actual completion time

Gantt Chart 

Example Diagram Figure 2-4

PERT Chart   

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Program Evaluation and Review Technique (PERT) is a planning and control tool Also known as Network Diagram or Critical Path Graphically portrays the optimum way to obtain a desired objective with respects to time Optimistic, average, and pessimistic time estimates utilized

PERT Chart 

Example Diagram Figure 2-5

Job/Worksite Analysis Guide Perform a walkthrough observing the area, worker, task, environment, administrative constraints, etc…  Develop an overall perspective of the situation  Particularly useful in workstation redesign 

Job/Worksite Analysis Guide 

Example Guide Figure 2-6

Recording and Analysis Tools Operation Process Chart  Flow Process Chart  Flow Diagram  Worker and Machine Process Charts  Gang Process Charts 

Operation Process Chart 

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Chronological sequence of all operations, inspections, time allowances, materials Depicts entrance and exit of all components and sub-assemblies and products Provides information on the number of employees required time for jobs and inspections

Operation Process Chart 

Example Diagram Figure 2-8

Flow Process Chart  

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More detailed, fit for closer observation of smaller components or assemblies Shows all moves (distances) and storage delays (times) for product movement in plant Aids in the reduction of hidden costs, “Muda.” Can be beneficial for plant layout suggestions

Flow Process Chart 

Example Diagram Figure 2-11

Flow Diagram Pictorial representation of the layout of the plant  Good supplement to the Flow Process Chart 

Flow Diagram 

Example Diagram Figure 2-13

Worker and Machine Process Charts  

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Used to study, analyze, and improve one workstation Shows the time relationship between working cycle of the person and the operating cycle of the machine Reveals idle time for both machines and workers Establishes “TAKT” time

Worker and Machine Process Charts 

Example Diagram Figure 2-15

Gang Process Chart 

Example Diagram Figure 2-16

Quantitative Tools Synchronous Servicing  Random Servicing  Line Balancing 

Synchronous Servicing 

Assigning more than one machine to an operator

Random Servicing 

Helps to determine the number of machines to assign to an operator when it is not known exactly when each machine needs to be serviced or for how long

Line Balancing Helps to determine the ideal number of workers to be assigned to a production line  Computer software is available to eliminate the calculations 

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