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Equipment Performance Improvement/ Analysis and Problem Solving Tools, SPC
Equipment Performance Improvement/ Analysis and Problem Solving Tools, SPC
Equipment Performance Improvement/ Analysis and Problem Solving Tools, SPC
IMPROVEMENT/ ANALYSIS
AND PROBLEM SOLVING
TOOLS, SPC
Reported by:
Abillonar, Carlo L.
Jordan, Russell
Checklist
Histogram
Fishbone analysis / Diagram
Pareto Chart
Scatter diagram
Trend analysis
Failure Mode and Effect Analysis (FMEA)
TOPICS
A checklist is a type of informational job aid used to
reduce failure by compensating for potential limits of
human memory and attention.
It helps to ensure consistency and completeness in carrying out a
task.
A basic example is the "to do list." A more advanced checklist
would be a schedule, which lays out tasks to be done according
to time of day or other factors.
CHECKLIST
Histograms are graphs of a distribution of data designed to show
centering, dispersion (spread), and shape (relative frequency) of
the data.
Histograms can provide a visual display of large amounts of data
that are difficult to understand in a tabular, or spreadsheet form.
HISTOGRAM
1. Count the number of data points (50 in our height example).
2. Determine the range of the sample - the difference between the highest and lowest values
(73.1-65, or 8.1 inches in our height example.
3. Determine the number of class intervals.
You can use either of two methods as general guidelines in determining the number of
intervals:
A. Use ten intervals as a rule of thumb.
B. Calculate the square root of the number of data points and round to the nearest whole number.
In the case of our height example, the square root of 50 is 7.07, or 7 when rounded.
You may wish to experiment with different interval numbers. If there are too many, the distribution will
spread out, and the histogram will look flat. Likewise, if there are too few intervals, the distribution
can look artificially tight.
5. Develop a table or spreadsheet with relative frequencies for each interval, which becomes
a tabular histogram:
The histogram tool is a common tool for understanding data and
the characteristics of data. Knowing how to correctly read a
histogram graph can greatly assist process improvement efforts.
Because of a histogram's common use it also makes an excellent
graphic for representing data during presentations.
The Cause & Effect, or Fishbone Diagram, was first used by
Dr. Kaoru Ishikawa of the University of Tokyo in 1943 - hence
its frequent reference as a "Ishikawa Diagram". This diagram
is used to identify all of the contributing root causes likely to
be causing a problem.
FISHBONE DIAGRAM
the process is continued until all possible causes are listed
a good diagram will have several levels of bones and will provide
a very good overview of a problem and its contributing factors
the factors are critically analyzed in terms of their probable
contribution to the overall problem
FISHBONE DIAGRAM
Helps determine root causes
Encourages group participation
Uses an orderly, easy-to-read format
Indicates possible causes of variation
Increases process knowledge
Identifies areas for collecting data
Iron in
Product
Iron in
Product
Inexperienced
analyst Sampling
Lab solvent contamination
Iron in
Lab error Rust near sample
Product
Materials for construction
points
Rusty pipes
Dirty bottles
Opening lines
Inexperienced
Supplier In lab Iron tools
analyst Sampling
Lab solvent contamination
Iron in
Lab error Rust near sample
Product
Materials for construction
points
Rusty pipes
PARETO CHART
Some examples of the 80/20 Rule applications are:
80% of the process defects arise from 20% of the process issues.
20% of sales force produces 80% of company revenues
80% delays in the schedule arise from 20% of the possible causes
of the delays.
80% of the customer complaints arise from 20% of your products
or services.
PARETO CHART
In a Pareto analysis, relatively few factors generally account for a
large percentage of the total cases
Idea is to classify the cases according to degree of importance,
and focus on the most important, leaving the less important
PARETO CHART
ThePareto Chart is a simple to use and powerful
graphic to identify where the majority of problems in a
process are originating. Using a Pareto Chart early in
problem solving is an effective strategy to decrease
project complexity.
A scatter diagram is a tool for
analyzing relationships between
two variables, using a plot of
pairs of data on an x and y axis.
SCATTER DIAGRAM
When you have paired numerical data.
When your dependent variable may have multiple values for each
value of your independent variable.
When trying to determine whether the two variables are related, such
as:
TREND ANALYSIS
TREND ANALYSIS
FMEA is a systematic, proactive method for evaluating a process
to identify where and how it might fail and to assess the relative
impact of different failures, in order to identify the parts of the
process that are most in need of change.
To use the Risk Priority Number (RPN) method to assess risk, the
analysis team must:
Rate the severity of each effect of failure.
Rate the likelihood of occurrence for each cause of failure.
Rate the likelihood of prior detection for each cause of failure
REFERENCES