practical problem solving tools
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PRACTICAL PROBLEMPRACTICAL PROBLEM
SOLVING TOOLSSOLVING TOOLSTALLY SHEET
PARETO DIAGRAM
CAUSE AND EFFECT DIAGRAMBRAINSTORMING
5 WHYS
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OBJECTIVESUnderstand the common problem-solving techniques, applications and
methodology.Develop problem-solving skills amongall levels of organization personnel.
Understand the concept of QualityControl Circle as a means to study andsolve quality-related problems.
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What is a Tally Sheet?A tally sheet is a tool for
collecting the right data in asimple manner.
A. Recording Tally Sheets
1. Defective item tally sheet
2. Cause of defect tally sheet
3. Production process distributiontally sheet
B. Inspection Tally Sheets1. Checking and information tally sheet
2. Requested item tally sheet
3. Evaluation tally sheet
a b c d e
1
2
3
4
5
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EXERCISE 1Make a tally sheet from the data ofSummary DPR.
The tally sheet is about the frequencythat each injection machines has anOEE below 75% .
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What is a Pareto Diagram?Pareto diagram is defined in Japan IndustrialStandards Quality Control terminology as
follows:It is a diagram that shows by item and by classesthe order of the largest number of occurrencesand the cumulative sum total. For example,
classify the defective products according to defectcontent, arrange the ranking of the total numberof defects. Draw the diagram and rank importancewill be known.
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Brief History of Pareto
DiagramPareto diagram was first thought out by an Italianeconomist, Pareto (1848-1923); when he used itas a method form national income analysis to
show that a large proportion of the wealth wascentred around a small minority of people.
Then an American quality control authority, Juran,born in 1904, used it tin the field of QualityControl.
If used properly, the Pareto diagram will clearlyportray where the biggest defect or error or thewhereabouts of the problem is, the biggestinfluence, and the degree of magnitude of theproblem.
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Making a Pareto Diagram1. Set the method and time period for the data
collection. Collect the data classified
according to causes and subject matter.2. Arrange the items in such a way that the
item with the most data is entered first,followed by items with decreasing data. Add
up the cumulative figure.3. On a graph, draw in the vertical axis (y) andhorizontal axis (x). Put the scale unit in thevertical axis.
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Making a Pareto Diagram4. In the order of the most data, from the left,
draw in the bar graphs. Keep all the bars in
the same width. Do not leave any space inbetween the bars.
5. Using the cumulative figure, draw in thecumulative curve. From the bar graph
columns right corner, extend the line to theend, joining with a broken line graph.
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Making a Pareto Diagram6. Draw a line from the end of the bar graph
to the vertical axis. Where it intersects the
cumulative curve, it is taken as 100%. Putin the scales for the cumulative percentage.
7. Write in the title for the Pareto diagram, theperiod the data was collected, the total
number of data, the authors, etc.
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EXERCISE 2Make a Pareto Diagram using the dataof the tally sheet in exercise 1.
Dont forget to get the cumulativefigure of the data before making aPareto Diagram.
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BrainstormingAllows generation of a high volume ofideas quickly. Generally used integrally
with the advocacy team whenidentifying the potential Xs
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What is A Cause-And-Effect?
A cause-and-effectdiagram shows the
systematic relationshipbetween a fixed resultand its related causes.It is also called
fishbone diagrambecause of its shape.
Process
Defects
Man Machine Material
Method Measurement
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Making A Cause-And-Effect
1. Draw in the order of large, medium andsmall bones.
a. Decide on the effect. Write it on the right..
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1. Group the causes into large, medium and small
bones. (Via brainstorming)
a. L
et the group members come up with all thecauses they can on the effect.
b. Cluster the causes of the effect under large
headings and write into the bone. The large bone
should only have 4 to 8 branches
c. Write each cause into the middle and small
bones.
Making A Cause-And-Effect
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d.Check that nothing is omitted or overlaps.
e. Mark the cause that is the most important.
Making A Cause-And-Effect
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Pointers in Making a Causeand Effect Diagram
Do not mix up factors, causes and
countermeasures.
Accept all ideas of all circle members, no matter
how insignificant the opinions are.
Set the diagram up in a visible place for everybodyto see.
Do as many sheets as there are effects.
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Low output
At the stamping
section
MANPOWER MATERIALS
Lack of training
Rush jobs
MACHINE
Newly hired
employees
Do not want the
assigned job
Careless Operator
Issuance of defective
handles due to
molding process
Overlooked by
QA inspectors
Factory Defect
Defective
marking tapes
Poor quality
Slow heat generation by
the heater
Worn out
Defective foot switch
Lack of
maintenance
Unreported
METHOD
Defective
stamping jigsImproper lighting
facilities
Too many rejectedhandles due to stamping
process
Breakages
Overlapped or mis-aligned
stamped rating on
handlesMisplaced & lost
Slow set-up time of
jigs
Frequentreplacement of jigs
No line maintenanceToo much dependence of
maintenance personnel
Lack of
stamping jig
Lack of jig holders
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Exercise 3Make a fishbone diagram from the datain exercise 2.
Use brainstorming for gathering ofcauses.
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5 WhysIt is a tool for collecting the root causesof the problem by asking why after
each causes five times.
The cause of the 5th why is the mostprobable cause of the problem.
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ExampleProblem : Employees are frustrated &
complaining about the newe-mail system.
Why : Employees do not understand
how to use the function ofthe system.
Why : The employee didnt receiveadequate training on the
new system., a manualthey can use, and didnt giveinputs on their needs forthe new system functions.
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ExampleWhy : The IS manager has a poor
planning process: didnt ask
employees about their needson system functions, didntplan for training up front,didnt notify employees using
multiple communicationchannels, didnt review themanual with employees.
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ExampleWhy : The manager didnt get
direction and support from his boss, orreceive planning
process training.
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