Problem Solving Tools

1. Exploratory TOOLS

1.Pareto Analysis2.Fish Diagram3.Gantt Chart4.PERT Diagram5.Job/Worksite Analysis Guide

Pareto Diagram

When is it used and what results will be obtained?

Please refer to the table on next slide for the usage and benefits of a Pareto diagram. It is mainly used to prioritize matters, and because of its easiness of use, the diagram is used in a wide variety of fields.

Pareto Diagram Pareto Diagram ( No. of Occurrences)

Pareto Diagram Pareto Diagram ( No. of Occurrences)

Used to prioritize actions.(Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.)

Used to identify and prioritize a problem.

Used to review the effects of an action taken.

Allows clarification of important tasks.

Allows identification of a starting point (which task to start with).

Allows projection of the effects of a measure to be taken

Method Usage Result

Pareto Diagram

Cause & Effect Diagram

1. What is Cause & effect Diagram ?

A cause and effect diagram is “a fish-bone diagram that presents a systematic representation of the relationship between the effect (result) and affecting factors (causes).”

Solving a problem in a scientific manner requires clarification of a cause and effect relationship, where the effect (e.g., the result of work) varies according to factors (e.g., facilities and machines used, method of work, workers, and materials and parts used). To obtain a good work result, we must identify the effects of various factors and develop measures to improve the result accordingly.

Cause & Effect Diagram

When is it used and what results will be obtained?

A cause and effect diagram is mainly used to study the cause of a certain matter. As mentioned above, the use of a cause and effect diagram allows clarification of causal relation for efficient problem solving. It is also effective in assessing measures developed and can be applied to other fields according to your needs.

Can obtain a clear overall picture of causal relation. (A change in the cause triggers a variation in the result.)○Can clarify the cause and effect relationship.

Can list up all causes to identify important causes.

Can determine the direction of action (countermeasure).

Method Usage Result

Cause & Effect Diagram

Used when clarifying a cause and effect relationship.[Used during a phase to analyze causes.]

Used to develop countermeasures.

[Used during a phase to plan countermeasures.]

Material Method

ManMachine

Cause (4M’s) Result (Controlled State)

Eff

ect

Cause and Effect Cause and Effect DiagramDiagram

Material Method

ManMachine

Cause (4M’s) Result (Controlled State)

Eff

ect

Cause and Effect Cause and Effect DiagramDiagram

8

Cause & Effect Diagram

Mechanism of Copying Machine

Quality of Copying Paper

User Surrounding Environment

Smudges on the copied surface

Internal devices not working smoothly

Malfunction of the roller

Printing too lightly

Too thin

Folded

Running out of stock

Dampened

Keyboard handling error

Error in selecting a scale of reduction

Error in placement of paper (setting its face up)

Error in selecting shading

Deterioration of performance due to high temperatures

Nicotine-stained

Dirt on the glass surface

Dust

Man

y C

opyi

ng E

rror

s!

Mechanism of Copying Machine

Quality of Copying Paper

User Surrounding Environment

Smudges on the copied surface

Internal devices not working smoothly

Malfunction of the roller

Printing too lightly

Too thin

Folded

Running out of stock

Dampened

Keyboard handling error

Error in selecting a scale of reduction

Error in placement of paper (setting its face up)

Error in selecting shading

Deterioration of performance due to high temperatures

Nicotine-stained

Dirt on the glass surface

Dust

Man

y C

opyi

ng E

rror

s!

Gantt and PERT charts

Gantt Charts› Useful for depicting simple projects or

parts of large projects› Show start and completion dates for

individual tasks PERT Charts

› PERT = Program Evaluation Review Technique

› Show order of activities or dependencies between activities

Tutorial:PERT/CPM Chart

1

2

3

4

5

6

8

7

5

6

2

6

5 3

1

TE = 5

TE = 11

TE = 12

TE = 14

TE = 20

TE = 19 TE = 22

TE = 23

12

Task. A project has been defined to contain the following list of activities along with their required times for completion:

Activity No

Activity Expected completion time

Dependency

1. Requirements collection 5 -

2. Screen design 6 1

3. Report design 7 1

4. Database design 2 2,3

5. User documentation 6 4

6. Programming 5 4

7. Testing 3 6

8. Installation 1 5,7

a. Draw a PERT chart for the activities. b. Calculate the earliest expected completion time. c. Show the critical path.

a. Draw a PERT chart for the activities. Using information from the table, show the sequence of activities.

1

2

3

4

5

6

8

7

1

2

3

4

5

6

8

7

b. Calculate the earliest expected completion time. 1. Using information from the table, indicate expected completion time for each activity.

5

6

7

2

6

5 3

1

2. Calculate earliest expected completion time for each activity (TE) and the entire project.Hint: the earliest expected completion time for a given activity is determined by summing the expected completion time of this activity and the earliest expected completion time of the immediate predecessor. Rule: if two or more activities precede an activity, the one with the largest TE is used in calculation (e.g., for activity 4, we will use TE of activity 3 but not 2 since 12 > 11).

TE = 5

TE = 11

TE = 12

TE = 14

TE = 20

TE = 19 TE = 22

TE = 23

15

PERT/CPM Chart (the end)

1

2

3

4

5

6

8

7

5

6

2

6

5 3

1

TE = 5

TE = 11

TE = 12

TE = 14

TE = 20

TE = 19 TE = 22

TE = 23

c. Show the critical path.

The critical path represents the shortest time, in which a project can be completed. Any activity on the critical path that is delayed in completion, delays the entire project. Activities not on the critical path contain slack time and allow the project manager some flexibility in scheduling.

2. Recording and Analysis TOOLS

1. Operation Process Chart (OPC)2. Flow Process Chart3. Flow Diagram

Operations Process Chart

By superimposing the route

sheets and the assembly chart,

a chart results that gives an

overview of the flow within the

facility. This chart is operations

process chart.

Flow Process Chart

This chart uses circles for

operations, arrows for

transports, squares for

inspections, triangles for

storage, and the letter D for

delays. Vertical lines

connect these symbols in

the sequence they are

performed.

Flow Diagram

It depicts the probable

movement of materials in

the floor plant. The

movement is represented

by a line in the plant

drawing.