Problem solving tools

Systematic procedure

Obtaining and Development Present and

Project selection presenting Data analysis of the ideal install the
data method method

Development of job analysis Set time standards Follow up

Problem identification
First and crucial step

Operator uses tools for their jobs, what does the Engineer requires for the job?
Tools for methods analysis
Pareto diagram and Fish diagram → quality circles at the beginning of 1960

Cost reduction at processes

Improve quality

Gantt and PERT charts → 1940 - military complex projects

better planning and control of the projects

Project selection
Considerations:

1. Economic
2. Technical
3. Human
1. Economic
New products without standar

High cost manufacturing the product

Waste

Reworks

Excessive material handling

Bottle necks
Technical
Processing techniques that require improvement

Quality control problems due to method

Product operation problems

Human
Highly repetitive jobs

High rates of incidents

Works with excessive fatigue

tasks that workers constantly complain about

Pareto analysis
Developed by Vilfredo Pareto

is a very powerful tool for showing the relative importance of problems. It contains
both bars and lines, where individual values are represented in descending order
by bars, and the cumulative total of the sample is represented by the curved line.
It is a simple calculation technique.
Analyze the characteristics of a group and recognize the most important points
within it to prioritize them.
Observe the elements and focus your efforts towards a single objective.
It allows you to make objective decisions that are based on data and not personal
opinions.
Analyze the elements and the frequency with which each of the data occurs
Inventory control. The ABC inventory control system is based on the Pareto principle,
considering that 20% of the items in the warehouse generate 80% of the inventory
movements, so they are the ones on which the most attention must be paid.
Sales. 80% of closed sales come from 20% of the products, and the 20% of the most
loyal customers are the ones that generate 80% of the total profits, from which more
commercial and marketing strategies can be developed. effective.
Customer service. It is considered that 20% of product failures represent 80% of
customer complaints, so it helps to prioritize precise optimization to reduce incidents.
Production control. The use of the Pareto diagram helps to study which 20% of the
defects in a production produce 80% of the negative consequences of the procedures,
which helps to prioritize in the improvement program.
Human Resources. In the area of organizational development, the 80/20 rule can be
applied to identify problems such as absenteeism, since 80% of absences are mainly
due to 20% of the collaborators.
EXERCISE FOR PARETO

PROBLEM DOWN TIME

NO DOORS 25

TORQUE FAILURE 95

REWORK IN HARNESS INSTALLATION 15

REPAIR AIR BAG NUT 36

NO PRESSURE IN THE SHOWER TEST 27

Fish diagram
Also known as cause-effect diagram

Ishikawa 1950
Man

Method All factors are critically analyzed in terms of

their likely contribution to the entire problem.
Machine
This process may also tend to identify
Material potential solutions.

Environment
Gantt diagram
Started in 1940 as a necessity to administrate projects and complex defense
systems
Gantt Diagram
It was probably the first project control and planning technique that emerged
during the 1940s as a response to the need to manage complex defense projects
and systems.

Helps you to visualize if any task it’s ahead of the timing stablished or delay.

Unfortunately, this diagram does not always completely describe the interaction
between the different project activities. For this purpose, more analytical
techniques such as Perth diagrams are required.

This tool it’s used also for equipments

EXERCISE FOR GANTT
INSTALLATION OF NEW INJECTION
MOLDING EQUIPMENT

ACTIVITY TIME REQUIRED (DAYS)

EVALUATE EQUIPMENT 2
QUOTE EQUIPMENT 1
QUOTE PLATES 1
REQUISITION FOR EQUIPMENT 1
REQUISITION FOR PLATES 1
RECIEVE EQUIPMENT 21
RECEIVE PLATES 8
INSTALL EQUIPMENT 3
INSTALL PLATES 1
PROGRAM PARAMETERS 3
PILOT TESTS 1
CONFIRM QUALITY 1
STABLISH THE STD WORK 5
TRAING THE OPERATOR 2
PERT Diagram
Program Evaluation and review Technique, also known as the Network diagram

Planning and control tool that graphically portrays the optimal way to obtain a
predetermined objective Generally in terms of time

This technique was used by the US military to design processes such as the
development of the Polaris missile and the operation of nuclear submarine control
systems.
In a diagram the elements that are represented by nodes are positions in time that
show the beginning and end of a particular operation or group of operations. Each
operation or group of operations carried out in a department is defined as an
activity and They are called arches, each will have a number (time)
Activities that do not consume time or cost but are nevertheless necessary to
maintain a correct sequence are called dummy activities and are shown with
dotted lines.
The critical path is the longest sequence of tasks that must be accomplished to successfully complete a
project.

The goal is to find the longest path that will take the longest to calculate the shortest total project duration.
Time estimates can be calculated based on the following:

Duration being optimistic: The minimum amount of time necessary to perform a task.

Duration being pessimistic: The maximum amount of time needed to complete a task.

Most likely duration: The best estimate of how much time it will take to complete a task.
You can use the PERT formula to calculate the expected duration of a task and
the time of its completion as follows: (O + (4 × MP) + P) ÷ 6. This can be
measured in minutes, hours, days or even weeks.

For example, if the optimistic duration is 30 minutes, the pessimistic duration is 60

minutes, and the most probable duration is 45 minutes, the PERT formula would
look like this: (30 min + (4 × 45 min) + 60 min) ÷ 6 = 45 minutes.
EXERCISE FOR PERT

Actividad Sucesora Pessimistic Most likely Optimistic

Actividad C,D 40 30 20
B E 50 42 36
C E 18 9 8
D F 24 22 20
E F 60 56 52
F - 30 28 26
 B

C E

D
F
Logging and analysis tools
PROCESS DIAGRAM

Chronological sequence from the beginning to the end

From the arrival of raw materials to packaging

Circle = operation Square = inspection

Vertical lines indicate the overall flow of the process As work is performed while
horizontal lines feeding into the vertical flow lines indicate materials parts are
shown as entering a vertical line for assembly or a vertical line for assembly

The vertical flow lines and the horizontal material lines should not be crossed. If
the crossing is strictly necessary, the convention should be used to show that no
connection is present. In other words, a small semicircle is drawn.
Process flow diagram
It has much greater detail than the process diagram

Registers non-productive costs hidden, such as distances traveled, delays,

temporary storage.
Route diagram
Provides most of the pertinent information related to a manufacturing process.

It is a graphic representation of the plant layout that shows the location of all
activities in the process flow diagram.

Activities are identified using symbols and numbers corresponding to those that
appear in the process flow diagram.
Man-machine process diagrams
Used to study, analyze and improve one workstation at a time.

It shows the exact time relationship between the person's work cycle and the
machine's operating cycle.

Waiting time can be productive time

Group process diagram
How to interact different equipments