Problem Solving Tools
INSY 3021
Auburn University
Spring 2008

Exploratory Tools
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Pareto Analysis
Fish Diagrams
Gantt Chart
PERT Chart
Job / Worksite Analysis Guide

Pareto Analysis
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Items identified and ordered on common scale in decreasing frequency, creating a cumulative distribution
80/20 Rule: 20% of the items account for
80% of the problems
Allows the company to concentrate resources on the jobs with the most problems

Pareto Analysis
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Example Diagram
Figure 2-2

Fish-bone Diagrams
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Cause-and-effect diagrams
Identified problem or undesirable result is the “head”
Contributing factors are the “bones”
Typical categories include: Human, machine, methods, materials, environment, and administrative
Estimates associated probabilities

Fish-bone Diagrams
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Example Diagram
Figure 2-3

Gantt Chart
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Used for planning of complex projects
Shows expected start and completion times, also duration of events
Similarly, major events can be broken into smaller sub-tasks
Shade the bars to show actual completion time

Gantt Chart
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Example Diagram
Figure 2-4

PERT Chart
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Program Evaluation and Review Technique
(PERT) is a planning and control tool
Also known as Network Diagram or
Critical Path
Graphically portrays the optimum way to obtain a desired objective with respects to time
Optimistic, average, and pessimistic time estimates utilized

PERT Chart
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Example Diagram
Figure 2-5

Job/Worksite Analysis Guide
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Perform a walkthrough observing the area, worker, task, environment, administrative constraints, etc…
Develop an overall perspective of the situation
Particularly useful in workstation redesign

Job/Worksite
Analysis Guide
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Example Guide
Figure 2-6

Recording and Analysis
Tools
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Operation Process Chart
Flow Process Chart
Flow Diagram
Worker and Machine
Process Charts
Gang Process Charts

Operation Process Chart
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Chronological sequence of all operations, inspections, time allowances, materials
Depicts entrance and exit of all components and sub-assemblies and products
Provides information on the number of employees required time for jobs and inspections

Operation
Process Chart
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Example Diagram
Figure 2-8

Flow Process Chart
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More detailed, fit for closer observation of smaller components or assemblies
Shows all moves (distances) and storage delays (times) for product movement in plant
Aids in the reduction of hidden costs,
“Muda.”
Can be beneficial for plant layout suggestions

Flow Process
Chart
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Example Diagram
Figure 2-11

Flow Diagram
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Pictorial representation of the layout of the plant
Good supplement to the Flow
Process Chart

Flow Diagram
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Example Diagram
Figure 2-13

Worker and Machine
Process Charts
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Used to study, analyze, and improve one workstation
Shows the time relationship between working cycle of the person and the operating cycle of the machine
Reveals idle time for both machines and workers
Establishes “TAKT” time

Worker and
Machine
Process Charts
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Example Diagram
Figure 2-15

Gang Process Chart
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Example Diagram
Figure 2-16

Quantitative Tools
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Synchronous Servicing
Random Servicing
Line Balancing

Synchronous Servicing
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Assigning more than one machine to an operator

Random Servicing
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Helps to determine the number of machines to assign to an operator when it is not known exactly when each machine needs to be serviced or for how long

Line Balancing
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Helps to determine the ideal number of workers to be assigned to a production line
Computer software is available to eliminate the calculations

Questions & Comments