PROBLEM SOLVING TOOLSLets us improve our understanding on..

FLOW CHARTBRAIN STORMINGCAUSE AND EFFECT DIAGRAMDATA COLLECTIONGRAPHS AND CHARTSSTRATIFICATIONPARETO ANALYSISHISTOGRAMSCATTER DIAGRAMBOX AND WHISKER

FLOW CHARTA flow diagram is a graphic representation of sequence of steps that we perform same output. The output may be a physical product, a service, information or a combination of the three.

ProcessDecision BoxDocument / RecordConnectorExtended ProcessManual OperationManual Input

Develop a common understanding of an overall process. Uncover potential problems, bottle necks unnecessary steps and rework loops in the process. Guide the potential solution without having to observe the process physically.

FLOW CHART

InterpretationBetter understanding of the current process, as a whole, and common understanding.Estimation of cost of Quality.Develop plans for data gathering.Generate theories about root causes. Discuss ways to stratify the data for analysis, to identify root cause.Identify the need to streamline the process or changes in the process.Provide training on how the process should operate.

EXCERCISEDraw a Flow Chart for following process :- Rework of Non Conforming product. Disposition of Non Conforming In-coming material.

Cause EffectBasic to quality improvement is the need to identify the root cause of a problem. The cause effect diagram is an effective way to organize and display the various theories about what those root cause might be.

Visual Representation and Interrelationship among the possible factors and effect. (Aspect Impact Sheet)Strength

Focuses the the attention of all people in the team on the specific problem at hand in a structured and systematic way.Encourage innovative thinking.C-E diagram has a tremendous capability of communicating to others.Cause Effect

Step how to construct :-Define clearly the effect.Draw a arrow (thicker) and place the effect at the arrow.Use brain storming or a rational step- by-step approach to identify the possible causes.Each of the major cause placed and joined with central spine at 70 deg. Angle.Add causes for each main area and subsidiary cause till you reach at root cause.Check the logical validity of each cause chain.Check the completeness.Cause Effect

EXCERCISEDraw a Cause and Effect Diagram for following effects :- Mixing of Arm rear brake stopper Reducing Water Generation.

Stratification

Stratification is the separation of data into categories. Its most fragment use is during the diagnostic to identify categories contribute to the problem being solved.

Stratification Variable :- The Characteristic used to separate the data is called a stratification variable.

Stratification

Point out exactly the root cause.Which area needs further investigationInterpretation 1. Usually present the stratification results in bar chart .2. If no category stands out, look at another variable. Within each category of first variable.Pitfalls and Traps :-Conclude too much.Small difference / May be random error.

Exercise :-If a team is solving a problem for which no data exist, there is no point in making a list of variables or characteristics to be used in stratifying data.When a stratification does not indicate an obvious pattern, the exercise has been a waste of time.Stratification is a tool which applies well only to relatively simple situations with a limited number of variables.Stratification applies to situations dealing with methods and procedures as well as with technology.

When to Stratify :Identifying Projects COQ./COPQAnalyzing Symptoms.Testing theories. Steps :-1 Select the Stratification variable.2 Establish Category for each variable.3 Sort the observation.4 Display

Pareto Analysis Pareto Analysis is a ranked comparison of factor related to a quality problem. It helps a quality improvement project teams to identify and focus on the VITAL few factors.

Vilfredo (1848-1923)M.O. LorenzVital few useful many.

Break Point Awkward Zone.

Sheet1

ItemNumber of ErrorsPercent of TotalCumulative Percent of Total

G442929

J382555

M312175

Q161186

B8591

D5395

C3297

A1197

O1198

R1199

N1199

L11100

I00100

E00100

H00100

K00100

F00100

P00100

Total150

Sheet1

&A

Page &P

Percent of Total

Cumulative Percent of Total

Sheet2

Sheet3

If a Pareto analysis does not shows a clear cut break point usually takes the following approach :-Identify the those few contributor which counts for about 60% of the total effect.Call these vital few and begin the diagnostic journey.Once you find a some path and improve repeat the Pareto, the contributor that were in awkward Zone may now be among the vital few.Repeat 1-3.

When to use Pareto :-1. Prioritizing Problems.2. Analyzing Symptoms.3. Proving Effectiveness of remedy.

Misapplication :-Objective data rather then opinion.

BOX and WHISKER PLOTBox plots like histogram, provide a graphic summary of the patterns of variation in a set of data.The box plot is especially useful when working with small sets of data or comparing many different distribution.

BOX and WHISKER PLOTHIGHEST VALUETHIRD QUARTILEMEDIANFIRST QUARTILELOWEST VALUE

BOX and WHISKER PLOT

Sheet1

ItemNumber of ErrorsPercent of TotalCumulative Percent of Total

G442929

J382555

M312175

Q161186

B8591

D5395

C3297

A1197

O1198

R1199

N1199

L11100

I00100

E00100

H00100

K00100

F00100

P00100

Total150

Sheet1

29.333333333329.3333333333

25.333333333354.6666666667

20.666666666775.3333333333

10.666666666786

5.333333333391.3333333333

3.333333333394.6666666667

296.6666666667

0.666666666797.3333333333

0.666666666798

0.666666666798.6666666667

0.666666666799.3333333333

0.6666666667100

0100

0100

0100

0100

0100

0100

&A

Page &P

Percent of Total

Cumulative Percent of Total

Sheet2

ContractorResponse time in minutes

12345678910

A45183207226243251268272290345

B102125145156188192215228251279

Sheet3

Sheet1

ItemNumber of ErrorsPercent of TotalCumulative Percent of Total

G442929

J382555

M312175

Q161186

B8591

D5395

C3297

A1197

O1198

R1199

N1199

L11100

I00100

E00100

H00100

K00100

F00100

P00100

Total150

Sheet1

29.333333333329.3333333333

25.333333333354.6666666667

20.666666666775.3333333333

10.666666666786

5.333333333391.3333333333

3.333333333394.6666666667

296.6666666667

0.666666666797.3333333333

0.666666666798

0.666666666798.6666666667

0.666666666799.3333333333

0.6666666667100

0100

0100

0100

0100

0100

0100

&A

Page &P

Percent of Total

Cumulative Percent of Total

Sheet2

ContractorResponse time in minutes

12345678910

A45183207226243251268272290345

B102125145156188192215228251279

Contractor

AB

Minmin45102

First Quartile((1)n+2) / 4207145

Median(n+1)/2247190

Third Quartile((3)n+2) / 4272228

Maxmax345279

Sheet3

Median response time of B is better than A.Variability of A is high than BEven though the A had shortest response time only about 25% of As response time were less than 207, while 75% of Bs were less than 228min.Nearly 25% of As response times were longer than Bs longest response time.

Comparing Patterns of variationsDifferences in the location of the MEDIAN.Differences in the amount of the variation.The presence or absence of outliers.Symmetry or asymmetry in the data.

BOX PLOT Vs HISTOGRAMBox plot indicates about the width of variation and the presence of various forms of asymmetry. Whereas, Histogram provides information about distribution of data along with width of variation and central tendency.

BOX PLOT Vs HISTOGRAM

Potential Pitfalls and problems in interpretationCurrent condition true data representation .More than 40 points - good enough.Just help you / lead you to establish a THEORY, which needs further confirmation.