PROBLEM SOLVING

TECHNIQUES
 Graphical Problem solving Techniques
PROBLEM SOLVING PROBLEM ANALYSIS
IDENTIFICATION

HISTOGARM
FLOW CHART PRETO CHART
SCATTER DIAGRAM
CHECK SHEET EFFECT DIAGRAM
CONTROL CHART
RUN CHART
 FLOW CHART
 A flow chart is pictorial representation showing all of
the steps of a process. it is a useful tool for
examining how various steps in a process are related
to each other. By studying these charts you can often
uncover loop holes which are potential sources of
trouble. The people with the knowledge of process
meet to:
 1.Draw flow chart of what steps the process actually
follows
 2.Draw a flow chart of what steps the process should
follow if every thing worked right.
 3.Compare the two charts to find where the problem
arise.
 CHECK SHEET
 Check sheet is a simple document that is used
for collecting data in real time & at the location
where the data is generated. The document is
typically a blank form that is designed for
quick, easy & efficient recording of the desired
information, Which can be either quantitative
or qualitative. when the information is
quantitative then it is also called tally chart.
CHECK SHEET
 PARETO DIAGRAM
 A Pareto diagram is a special form of
vertical bar graph which helps us to
determine which problem to solve in what
order. Doing a pareto chart based on the
data collection, helps us to direct our
attention & efforts to the truly important
problems. We can gain more by working on
the tallest bar than tackling the smaller one.
PROCESS REJECTION DATA FROM OCT '08 TO NOV '08

GEAR
T OT A L TAPPI GRINDI
BROACHI % REJ. % REJ. % AGE % REJ. % REJ. SHAVIN % REJ. SHAPIN % REJ. % AGE
C OM P IN SP . DRILLING NG HOBBIN HOBING NG
NG G G
MONTH G (SPL) (TEETH)
Oct,2008 32387 4 0.01 0 0.00 0 0.00 147 0.45 433 1.34 546 1.686 0 0 172 0.531
Nov,2008 38835 9 0.02 1 0.00 7 0.02 152 0.39 282 0.73 579 1.491 43 0.111 150 0.386
Dec,2008 16110 6 0.04 6 0.04 8 0.05 170 1.06 94 0.58 299 1.856 5 0.031 132 0.819
TOTAL 87332 19 0.02 7 0.01 15 0.02 469 0.54 809 0.93 1424 1.631 48 0.055 454 0.52

PROCESS REJECTION PARETO

3.00 98 99 100 100 100 100

96
90
85
80
74
70
% AGE REJ

2.00
1.631 60
54
50
0.978 0.926 40
1.00 34
30
0.537 0.520 0.520
20
0.055 0.022 0.017 0.008 10
0.00 0
SHAVING BORE HOBING HOBBING GRINDING MAT. GEAR BROACHING TAPPING DRILLING
GRINDING (TEETH) (SPL) HANDLING SHAPING
 CAUSE & EFFECT DIAGRAM
The cause & effect diagram was developed to represent
the relationship between some “effect” and all the
possible “causes” influencing it. For every effect there
are likely to be several major categories of causes.
The major causes might be summarized under four
categories referred to as the 4M’s :
MAN,MACHINES,METHODS,& MATERIAL.A well
detailed cause & effect diagram will take on the shape
of fish bones and hence it is also called Fish Bone
Diagram. From this well defined list of possible causes,
the most likely are identified & selected for further
analysis Remember, look to cure the cause and not
the symptoms of the problems.
CAUSE & EFFECT DIAGRAM
 2. Data Collection & Analysis
CAUSE & EFFECT DIAGRAM
MACHINE MATERIAL

FEED
CENTRE FACE R/O
POWER COMPONENT
DAMAGE
FAILURE CENTRE
DAMAGE
INSERT
HYDRAULIC BLUNT
PRESSURE HARDNESS
VARIATION CENTRE
FACE DRIVE DEPTH
WORN OUT VARIA.
CENTRE TOOL EXCESS
R/O MORE HOLDER MARGIN
LOOSE

DEEP TOOL
MARK
NEGLIGENCY

LACK OF STRAIGHTNING
AWARENESS

IMPROPER
TRAINING

MAN METHOD

11
 RUN CHART
 Run charts give a picture of a variation in
some process over time and help detect
special (external) causes of that variation.
They make trends or other non-random
variation in the process easier to see and
understand. With the understanding of
patterns and trends of the past, groups
can then use run charts to help predict
future performance.
RUN CHART
 HISTOGRAM
 A histogram is used to graphically summarize and
display the distribution of a process data set. A
histogram can be constructed by segmenting the
range of the data into equal sized bins (also called
segments, groups or classes). For example, if your
data ranges from 1.1 to 1.8, you could have equal
bins of 0.1 consisting of 1 to 1.1, 1.2 to 1.3, 1.3 to
1.4, and so on.
 The vertical axis of the histogram is labelled
Frequency (the number of counts for each bin), and
the horizontal axis of the histogram is labelled with
the range of your response variable.
HISTOGRAM
 SCATTER DIAGRAM
 A Scatter diagram is used to study the possible
relationship between one variable and another.
The scatter diagram is used to test for possible
cause & effect relationships. A scatter diagram is
set up whereby the horizontal axis (x-axis)
represents the values of one variable , and
vertical axis (y-axis) represents the values of
second variable. The more that this cluster
resembles a straight line, the stronger the
relationship. This makes sense that every time
one variable would change the other would
change by the same amount.
 CONTROL CHARTS
 A Control chart is simply a run chart with
statistically determined upper & lower
control lines drawn on either side of the
process average. These limits are
calculated by running a process untouched
,taking samples & plugging the sample
averages into the appropriate formula.
Now you can plot the sample average
onto the chart to determine whether any
of the points fall between or outside of the
limits or form unnatural patterns.If either
 STEPS FOR CONTROL CHART

 STEP 1: Gather the data for 50

consecutive samples running the process
untouched.
 STEP 2: calculating X-BAR,UCL & LCL (as
shown in the next sheet)
THANKS