Problem Solving Tools INSY 3021 Auburn University Spring 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 Diagram Figure 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 Diagram Figure 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 Diagram Figure 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 Diagram Figure 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

Example Guide Figure 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

Example Diagram Figure 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

Example Diagram Figure 2-11

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

Example Diagram Figure 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

Example Diagram Figure 2-15

Example Diagram Figure 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

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