Problem Solving Tools

INSY 3021

Auburn UniversitySpring 2008

Pareto Analysis Fish Diagrams Gantt Chart PERT Chart Job / Worksite Analysis Guide

Exploratory Tools

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 DiagramFigure 2-2

Pareto Analysis

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 DiagramFigure 2-3

Fish-bone Diagrams

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 DiagramFigure 2-4

Gantt Chart

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 DiagramFigure 2-5

PERT Chart

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

Job/Worksite Analysis Guide

Example GuideFigure 2-6

Operation Process Chart Flow Process Chart Flow Diagram Worker and Machine

Process Charts Gang Process Charts

Recording and Analysis Tools

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

Operation Process Chart

Example DiagramFigure 2-8

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

Flow Process Chart

Example DiagramFigure 2-11

Pictorial representation of the layout of the plant

Good supplement to the Flow Process Chart

Flow Diagram

Example DiagramFigure 2-13

Flow Diagram

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

Worker and Machine Process Charts Example Diagram

Figure 2-15

Example DiagramFigure 2-16

Gang Process Chart

Synchronous Servicing Random Servicing Line Balancing

Quantitative Tools

Assigning more than one machine to an operator

Synchronous 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

Random Servicing

Helps to determine the ideal number of workers to be assigned to a production line

Computer software is available to eliminate the calculations

Line Balancing

Questions & Comments