MAPÚA UNIVERSITY

658 Muralla St., Intramuros, Manila

School of Mechanical and Manufacturing Engineering

Research No. 2
Ishikawa Diagram, 4M and an E, Pareto Diagram,
Spider Web Diagram and Why Why Analysis

Name: Gorostiza, John Vincent D.

Student No.: 2011108243
Program / Year: MFGE – 4
Course / Section: MFGE27/E01 GRADE

Engr. Mitchelle Anthony Mirto

Instructor
 Ishikawa Diagram

Ishikawa diagram, also known as the fishbone/cause-effect diagram that helps to

visualize the potential causes of a problem to identify the root causes of the problem. A
fishbone diagram is useful in brainstorming sessions to focus conversation. After the
group has brainstormed all the possible causes for a problem, the facilitator helps the
group to rate the potential causes according to their level of importance and diagram a
hierarchy.
The diagram looks just like a fish’s skeleton with the problem at its head and the
causes for the problem feeding into the spine. Once all the causes that underlie the
problem have been identified, managers can start looking for solutions to ensure that
the problem doesn’t become a recurring one.

Operations Outage

A production line goes down for three shifts due to a failed machine. A root cause
analysis determines that the machine had multiple design issues. Such problems
weren't detected or mitigated by maintenance processes. When the machine needed to
be replaced, several issues complicated the process making the outage longer.
 4M and an E

a. Man: All human resources related matter such as direct labor & indirect labor, hiring
& firing, training, wages & benefits, knowledge & experiences, etc should roll under this
category.
b. Machine: Anything related to equipments, testers, jigs, fixtures, calibrations,
specifications of the machine, templates, pallets, tables & chairs, tools, etc.
c. Method: Any methods, instructions, specifications, guide, tolerance, etc.
d. Material: This applies to both direct & indirect materials.
 Direct materials are the list of materials that is listed in the BoM (Bill of Material).
They can be easily counted.
 Indirect materials are materials that are not listed in the BoM (Bill of Material).
Alternatively, they can be items that are difficult to count. For example the
materials that are in liquid, semi-solid and powdery form.
e. Environment: This applies to work station, temperature, ESD (Electro-Static Sensitive
Device), moisture sensitive devices, air conditioned, humidity, vibration, air pressure,
clean room environment, dust free requirement, etc. This is a rather small portion, but
anything that is related to environment will fall under this category.

The purpose of this procedure is to define the steps to do a 4M Analysis of a

system or subsystem. The goal of this 4M Analysis Procedure is to reduce losses in the
factory by using the Equipment Attributes as a guideline to achieve this end.
 Pareto Diagram

A Pareto chart, named after Vilfredo Pareto and originally created by Kaoru
Ishikawa, is a type of chart that contains both bars and a line graph, where individual
values are represented in descending order by bars, and the cumulative total is
represented by the line.

The left vertical axis is the frequency of occurrence, but it can alternatively
represent cost or another important unit of measure. The right vertical axis is the
cumulative percentage of the total number of occurrences, total cost, or total of the
particular unit of measure

The Pareto Chart shows the relative frequency of defects in rank-order, and thus
provides a prioritization tool so that process improvement activities can be organized to
"get the most bang for the buck", or "pick the low-hanging fruit". Following is an example
of paint defects from an automotive assembly plant:
 Spider Web Diagram

Spider Web Chart, also called radar chart, a graphical method to represent
multivariate data in the form of a two-dimensional chart of three or more quantitative
variables. It is useful for rating an item or items along 3 or more axes.

Initial Profile
The company in this initial profile manufactured architectural windows. The blue
profile shows their actual initial score prior to lean efforts. The red line indicates the
strategic goal for each area. Gaps between actual and goal indicate the most serious
deficiencies and lead to priorities.
Profile after 9 months

After nine months of intensive activity, all areas showed considerable improvement.
Priorities might now be shifted towards those areas with the largest current gaps.
 Why Why Analysis

The 5 Whys is an iterative interrogative technique used to explore the cause-

and-effect relationships underlying a particular problem. The primary goal of the
technique is to determine the root cause of a defect or problem by repeating the
question "Why?". Each answer forms the basis of the next question. The "5" in the
name derives from an anecdotal observation on the number of iterations needed to
resolve the problem.

Frequent belt snaps in the primary transmission drive in the grinding machine. A series
of repetitive Why’s are asked to identify the underlying root cause of the failure.