Problem-Solving Tools

Exploratory and Recording and

Analysis Tools

Agenda

!Defining the problem - Exploratory Tools

!Documenting the process - Recording

and Analysis Tools

!Determine proper worker - machine

relationships - Quantitative Tools (Part

II)

Methods Engineering Process

! Select project

! Get and present data

! Analyze data

! Develop idealmethod

! Present and install

method

! Develop job analysis

! Establish time

standards

! Follow up

Selecting the Project

!Considerations

!Economic

!Human

!Technical

Pareto Chart

!Developed by economist Vilfredo Pareto

!The critical few >> 80-20 rule

! Items of interest are identified and

measured on a common scale

Pareto Chart

Stream Diagnostic Chart

! List of problems classified under Man,Machine, Methods, Materials orManagement (or whichever isapplicable)

! The cause is attached to the tail of thearrow and the arrowhead is pointing tothe effect

! Focus on problem with most

outgoing/incoming arrows

Stream Diagnostic Chart Fishikawa Diagrams

!Cause-and-effect diagrams

!Occurrence of undesirable effect - the

fish head

! Identifying contributing factors or

causes - the fish bones

!Principal cause are also divided into

Man, Machine, Methods, Material,

Management, etc.

Fishikawa Diagrams Gantt Chart

!Project planning and control tool

!Shows anticipated completion times for

activities as bars plotted against time on

the horizontal axis

Gantt Chart

Job/Worksite Analysis Guide

! Identifies problems within a particular

area, department or worksite

Job/Worksite

Analysis Guide Other Tools

!Brainstorming (Structured and

Unstructured)

!Nominal Group Technique

!Check Sheet

Get and present data

!Documenting the present method

!Production quantities, schedules,

operation times, facilities, machine

capacities, special tools and materials

Operation Process Chart

!Chronological sequence of operations,

inspections, time allowances and

materials used in a process

!Gives manufacturing details at a glance

Operation Process Chart

Operation Process ChartFlow Process Chart

!More detailed than OPC

!Used for components rather than entire

assemblies

!Records non-production hidden costs

! Distances traveled, delays, temporarystorages

Flow Process Chart

Flow Process

Chart Flow Diagram

!Drawing of the plant areas involved with

a sketch of the flow lines indicating the

movement of material from one activity

to the next

!Uses same symbols as FPC

Flow

Diagram

Worker-Machine Process Chart

!Used to study, analyze, and improve

one workstation at a time

!Shows the exact time relationship

between the working cycle of the

person and the operating cycle of the

machine

Worker-Machine

Process ChartGang Process Chart

Gang Process

Chart Analyze Data

!Question every detail

!Why, Where, What, Who, When, How