week-1.2 problem solving tools 1

END 202END 202Work Analysis and DesignP bl S l i T l 1‐ Problem Solving Tools 1 ‐

Sibel ALUMUR ALEV

January 2011

END 202 – Work analysis and design Problem Solving Tools 1

Methods engineering

• A technique for increasing the production per unit time or decreasing the cost per unit output – productivity improvementp p y p

• Synonymous terms: Operation analysis, work design work simplificationwork design, work simplification, corporate engineering


Method engineering steps

1. Select project (Pareto, Fish diagram, Gantt, PERT)2 Get and present data (charts computations)2. Get and present data (charts, computations)3. Analyze data (operation analysis)4 Develop ideal method (motion work equipment4. Develop ideal method (motion, work, equipment

design)5. Present and install method (decision making tools)( g )6. Develop job analysis7. Establish time standards (time study)8. Follow up



1. Select project (Pareto, Fish diagram, Gantt, PERT)2 Get and present data (charts computations)2. Get and present data (charts, computations)3. Analyze data (operation analysis)4 Develop ideal method (motion work equipment4. Develop ideal method (motion, work, equipment

design)5. Present and install method (decision making tools)( g )6. Develop job analysis7. Establish time standards (time study)8. Follow up


Project selection

• The first and perhaps most crucial step is the identification of the problem in a clear pand logical form

• Typically project selection is based on 3• Typically project selection is based on 3 considerations:

– Economic

– Technicalec ca

– Human


Project selection

Exploratory tools:1 P A l i1. Pareto Analysis

2. Fish Diagrams

3. Gantt Chart

4 PERT Charting4. PERT Charting

5. Job/Worksite Analysis Guide


1. Pareto analysis

• V. Pareto originally observed that in Italy, 80% g y y,of the land was owned by 20% of the people

• Pareto Principle : 80‐20 Rule (80% of the effects stem from 20% of the causes)

– Customer Complaints: 80% of the complaints come from 20% of the customersfrom 20% of the customers

– Sales: 80% of the profits come from 20% of the productsproducts

– Quality Management: 80% of the problems come from 20% of the causes

– Inventory Management: 80% of the total inventory is found in 20% of the inventory items


1. Pareto analysis

• The aim is to identify the most important factors defects or problemsfactors, defects, or problems

• How to draw a Pareto chart?– Items of interest are identified and

measured on a common scale and then ordered in descending order as a cumulative distribution


1. Pareto analysis


1. Pareto analysis

Exercise: Draw a Pareto chart for being late to classDraw a Pareto chart for being late to class .


2. Fish diagrams

C d ff di• Cause‐and‐effect diagrams

• Developed by Ishikawa in the early 1950s

• Effect: fish head & Causes: fish bones

• Principle causes: human machines methodsPrinciple causes: human, machines, methods, materials, environment, administrative

• Provides good overview of a problem and its• Provides good overview of a problem and its contributing factors

Ai i t li t ll ibl t h l t id tif• Aim is to list all possible causes to help to identify potential solutions


2. Fish diagrams


2. Fish diagrams

Exercise: Draw a fish diagram for public bus latenessDraw a fish diagram for public bus lateness.


3. Gantt chart

• Shows the anticipated completion time for various project activities as bars plotted againstvarious project activities as bars plotted against time on the horizontal axis

• One can determine which project components• One can determine which project components are ahead or behind schedule

b h b• Project‐based or machine‐ or process –based


3. Gantt chart


4. PERT Charting

• Program Evaluation and Review Technique (PERT)(PERT)

• PERT is a model for project management designed to analyze and represent the tasksdesigned to analyze and represent the tasks involved in completing a given project. It is commonly used in conjunction with the criticalcommonly used in conjunction with the critical path method (CPM).


4. PERT Charting

Steps:1. Determine the events (tasks) and order them2. Estimate time for each task (most likely, optimistic,

pessimistic)pessimistic)3. Find the expected time for each task4. Create a network diagram (activity on arrow‐AOA or

activity on node‐AON)5. Find

• The early start time (ES)The early start time (ES)• The early finish time (EF)• The late start time (LS)• The late finish time (LF)• The late finish time (LF)• The slack

6. Determine the critical path


4. PERT Charting

Example (fromWikipedia):Example (from Wikipedia):

Time estimatesExpected

Activity PredecessorExpected timeOpt. (O)

Normal (M)

Pess. (P)

A — 2 4 6 4.00A 2 4 6 4.00

B — 3 5 9 5.33

C A 4 5 7 5.17

D A 4 6 10 6.33

E B, C 4 5 7 5.17

F D 3 4 8 4 50F D 3 4 8 4.50

G E 3 5 8 5.17


4. PERT Charting

Activity on node (AON) network diagram

D

A F

CFinishFinish

Start

B E G


4. PERT Charting

Activity on arrow (AOA) network diagram

5D

2

DF

6

A

C1

6

BE

G

3 4E


4. PERT Charting


4. PERT Charting

Advantages of PERTAdvantages of PERT

• It make the dependencies visible

• It ll t id tif th iti l th• It allows to identify the critical path

• It allows to reduce the project duration with a better understanding

Disadvantages of PERT

• With hundreds or thousands of activities difficult to see the dependencep

• Several pages to print, difficult to read


5. Job/Worksite analysis guide

• Allows to identify the problems within a particular area, department or worksite

• The analyst walks in the area, observes the worker, the task, the workplace and the psurrounding working environment

• The analyst also indentifies any administrativeThe analyst also indentifies any administrative factors that may affect the worker’s behavior or performanceor performance



Exercise: Watch the sewing machine video and fill out the guide.out the guide.


week-1.2 problem solving tools 1

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