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11 Quality - Problem Solving Tools


Slide 1

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Appendix 1
Problem Solving Tools

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skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

TBM Consulting Group, Inc. is the sole licensee of LeanSigma, a service mark of Maytag Corporation.

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Slide 2

Problem Solving Tools
? 5W1H ? Check Sheets ? Pareto Diagrams ? Cause/Effect Diagram

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skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 3

5W1H
? What data was collected ? Why was it collected ? When was it collected ? Who collected it ? Where was it collected from ? How will we use the data
Use the 5W1H methodology to grasp the current situation through good, useful data collection
skb Revised: 1/02 ? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 4

Check Sheets
The check sheet is a form, in diagram or table format, that is prepared in advance with the known defect type information. It is used to record defects simply by making a check mark on the form.

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Purpose of Check Determine # of occurrences of known defects Determine type of defect by day, operator, machine, etc. Determine where defect occurs Determine variation in dimensions, weight, temp., etc.
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Type of Check Sheet Defective item check sheet Defect factor check sheet Defect position check sheet Process variation check sheet
? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 5
Defect Item Bad Rubber Cracks

Defective Item Check Sheet
Day Mon Tues Wed Thu Fri Total 19 11 8 10 3 9 15 9 11 13 12 60

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5

Poor Adhesion Voids Cuts Other Totals

skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 6

Check Sheets
Defect Factor Check Sheet

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Mach # 475 Prs.

Die # 421A 422A 421A 422A

Mon

Tue

Wed

Thu

Fri

Totals 9 5 11 9

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470 Prs.

30

- Thickness Variation - Cracks - Surface Scratches - Other

skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 7

Pareto Diagrams
How to make a Pareto Diagram: Step 1: Decide which items to study and collect data.

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Defective Items Bad Rubber Cracks Poor Adhesion Voids Cuts Other

Number of Defects 19 11 8 10 3 9

skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 8
Step 2: Tabulate data and calculate the cumulative number
No. 1 2 3 4 5 6 Defective Items Bad Rubber Cracks Voids Poor Adhesion Cuts Other Total # of Defects 19 11 10 8 3 9 60 Cumulative 19 30 40 48 51 60 60
8

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skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

Slide 9
? Step 3: Draw the horizontal and vertical axes ? Step 4: Display the data as a bar graph ? Step 5: Draw the cumulative curve
60 50 40 30 20 10

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Bad Rubber
skb Revised: 1/02

Cracks Voids

Poor Adhes'n

Cuts

Other

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? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 10
? Step 6: Create a percent scale on the right vertical axis ? Step 7: Label the diagram ? Step 8: Examine and understand the data
150

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100% 120 80 90 60

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60 42 37 30 21 17 14 10 20 40

1

2

3

4

5

6

skb

Revised: 1/02

? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 11

Downtime Check Sheet and Pareto Chart
Downtime Reason Part misfeeds Vision system shutdown Lack of parts Limit switch Part jam ups Other / Day 1 10 5 2 11 2 6 2 6 6 4 6 3 3 3 12 4 3 8 3 2 4 9 2 2 5 2 4 5 5 4 3 7 2 Total 42 21 14 37 10 17 Rank 1 3 5 2 6 4

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150 100% 120 80 90 60 60

42 37

40

30

21 17 14 10

20

1
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2

3

4

5

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? 2002 TBM Consulting Group, Inc. All Rights Reserved.

Revised: 1/02

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Slide 12

Downtime Cause & Effect Diagram
Feeder Track Burrs Width Variation Alignment Friction Part Dimension

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Part Misfeeds
Vibration

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RPM Tolerance Dust/Dirt Worn Gears Timing
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Environment
? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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Slide 13

Developing the Diagram and Countermeasures
1. List all known causes 2. Establish major cause categories (Relations Diagram) 3. Categorize minor causes on Fishbone chart 4. Brainstorm countermeasures 5. Test, trial and measure results of countermeasures 6. Standardize improvements (procedures, standards)
skb Revised: 1/02 ? 2002 TBM Consulting Group, Inc. All Rights Reserved.

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