1. Forms & Activities used on
ISE - type Projects
Steve Snelling

2. List of Main Forms/Activities
Project Profile & Schedule
Tours
Observations
Time Studies
Informational Interviews
Plus/Minus chart
Process Flow chart
Cause/Effect diagram
Defect locator
(Measles) chart
Precedence chart
& Critical Path
Data Analysis
Pareto (80/20) chart
5-Whys diagram
Facility layout drawing
From/To chart
Activity Relationship chart
Space Utilization chart
5S Score chart
Spaghetti chart
(foot path/distance)
Value Stream map
Ergo Risk analysis chart
Benchmarking
FMEA (Failure Mode & Effect Analysis) chart
Comparison of Alternatives
Gap-to-Goal chart
Simulation 2

3. Sample Forms
Project Profile
Project Schedule 3

4. Sample Forms Time Study Process Flow Chart
Cause & Effect (Fishbone) Diagram
Best Kitting
Number of Kits Required
Volume of Inventory Required
Size of Kitting Area
Number of Kitters Working
Frequency of Replenishment
Number of Production Areas Supported
Spaghetti (foot path/distance) Chart
Effect
Causes 4

5. Facility Layout Drawing
Sample Forms
Value Stream Map
Facility Layout Drawing
5S Score Chart
Comparison Chart
Simplify
Sweep
Standardize
Sort
Self Actualize 5 4 3 2 1 3 2 3 2 5

6. Activity Relationship Chart
Sample Forms
Activity Relationship Chart
Precedence Diagram
(and Critical Path)
Shows importance of each department to other departments
Digital Picture
Pareto (80/20) Chart 6

7. Space Utilization analysis
Sample Forms
Gap-to-Goal Chart
Space Utilization analysis
CURRENT STATE
FUTURE STATE
GAPS
Decrease incidents by 50%
Incidents have been occurring
Improvement Project
is to be started
Process:
Plan View of Factory
Parts
Storage
Aisle
Packing
& Shipping
Machining
Center
Heat
Treating
Shows activity needed to reach a Goal
Data Analysis
75% utilization of available floor space
(25% free space)
Defect Locator ( “measles” ) Chart
Defects 7

8. Sample Forms From/To Chart A B C D E F Ergonomic Data FEMA
Departments
To Departments A B C D E F
100 ft.
200 ft.
75 ft.
25 ft.
50 ft.
35 ft.
FEMA
(Failure Mode & Effect Analysis)
Severity x Occurrence x Detection
= Risk Priority Number (RPN)
Highest RPN activity is worked first
Severity
Occurrence
Detection
Least
Most 10 1 2 3 4 5 6 7 8 9
Shows Travel Distance between departments
Ergonomic Data
Sev x Occ x Det = RPN
3 x x = 75 8

9. Sample Forms 5-Whys Diagram Plus/Minus Chart Start a New IE Project? 9
Problem
Statement
Why?
Major Potential Cause
Detailed Potential Causes
Root Causes
Welding failed
Weld temp. was low
Thermostat not set properly
Mechanic not trained
Mechanic could not see the temp. setting
Old
thermostat/ Faulty
reading
No documenta tion
Training not a requirement
Equipment not ordered/ order new equip.
Write temp. requirement
Make training a requirement
Not enough light
Provide adequate lighting
Start a New IE Project?
Driving (Positive) Forces
Impeding (Negative) Forces
Will save money
for company
Helps dept. goals
Meets IE goals
Helps production shop
Reduces flow days
Improves throughput
No help from shop,
they are busy
Low priority given
Difficult to get data
No guidance
No sponsors
of project
This example shows the reasons
for & against, starting a new IE project.
This example looks at Why a welding failed. 9

10. Informational Interviews
Sample Activities
Tours / Observations
Benchmarking
Organize the tour with the process owner
Get a guided tour
See the surrounding areas on the tour
Try to see normal conditions
Ask lots of questions during the tour
Take notes and debrief following the tour
Understand your own area and process first
Plan when to do the benchmarking within the project
Plan ahead what to Benchmark
Get good comparison information & data
Take notes and debrief following each benchmarking activity
Informational Interviews
Simulation
Prepare ahead who to talk to and some initial questions to ask
Make sure they are experienced with the task being investigated
Understand the problem from their perspective
Listen for items to follow-up on later
Don’t rush their answer to a complex question
Take good, organized notes
Understand your existing conditions before trying to build the simulation
Use standard software that your company uses
Build the model as simply as will meet your needs
Run all options being considered through the model
Document results and list all assumptions used 10