Problem Solving Tools INSY 3021 Auburn University Spring 2008.
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Transcript of Problem Solving Tools INSY 3021 Auburn University Spring 2008.
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Problem Solving Tools
INSY 3021
Auburn UniversitySpring 2008
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Pareto Analysis Fish Diagrams Gantt Chart PERT Chart Job / Worksite Analysis Guide
Exploratory Tools
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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
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Example DiagramFigure 2-2
Pareto Analysis
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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
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Example DiagramFigure 2-3
Fish-bone Diagrams
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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
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Example DiagramFigure 2-4
Gantt 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
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Example DiagramFigure 2-5
PERT Chart
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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
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Job/Worksite Analysis Guide
Example GuideFigure 2-6
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Operation Process Chart Flow Process Chart Flow Diagram Worker and Machine
Process Charts Gang Process Charts
Recording and Analysis Tools
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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
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Operation Process Chart
Example DiagramFigure 2-8
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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
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Flow Process Chart
Example DiagramFigure 2-11
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Pictorial representation of the layout of the plant
Good supplement to the Flow Process Chart
Flow Diagram
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Example DiagramFigure 2-13
Flow Diagram
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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
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Worker and Machine Process Charts Example Diagram
Figure 2-15
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Example DiagramFigure 2-16
Gang Process Chart
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Synchronous Servicing Random Servicing Line Balancing
Quantitative Tools
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Assigning more than one machine to an operator
Synchronous Servicing
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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
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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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Questions & Comments