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
 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
 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
 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
 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
 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
 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
Questions & Comments