Problem Solving

Techniques
Training Course
1
Ishikawa/ Fishbone
diagram

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 Ishikawa-/ Fishbone diagram

By the end of this module, you will be able to:

People

Orange
Materials Tables
Identify the Xs (inputs) and their
(1)
Bonders
Inspector
Tape

Teflon Pins
relationship to Y (output) using the
Dispatcher
Gloves
Thermocouples

Need 8 Lay-up Tables

Fishbone-/ Ishikawa Diagram
with Shelves

406/407/427
Yokes
Bladders
Floor Mats Around the
Allen Tool
Traveler
Wrenches
(2) Vacuum Lines
24" Wide Blue
Drill Motor
Tug or Other Prints
(1) Electric Lines
Method to Move
Bond Tools (2) Air Lines
Chains for Hoist
(2) Bond
(2) Tool Dollies
Hoist - 1 Ton Tools
Eddy Current Other
Equipment

Equipment/
Tools

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 Ishikawa-/ Fishbone diagram
What is it?
• A brainstorming tool

Objective or Purpose
• To facilitate a team brainstorming
session around the possible input
factors (causes) that effect the
project output.
• To assist teams in categorizing any
potential causes of problems or issues
in an orderly way.

When to Use It
• In the initial part of the measure
phase once the objective and
project scope have been clearly
defined.
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 Ishikawa-/ Fishbone diagram
Inputs Output

Measurements Materials People

Level 2
Level 1 Cause Level 1
Cause Level 1 Cause
Level 1 Cause
Cause

Output
Level 1
Level 1 Cause
Cause
Level 1 Level 2
Cause Cause

Environment Methods Machines

Identify potential causes driving variation in the output.

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 Ishikawa-/ Fishbone diagram
Step 1
Step 5 Draw the fishbone Step 2
Continue to ask why until no diagram. List the problem/issue (output
more useful information is Y) to be studied
produced. in the head of the fish.
Measurements Materials People
Level 2
Cause Level 1
Level 1 Cause
Level 1 Cause
Level 1 Cause
Cause
Output
Level 1
Level 1 Cause
Cause
Level 1 Level 2
Cause Cause

Environment Methods Machines

Step 3
Step 4 Label each bone
Brainstorm ideas to identify causes in of the fish with the
each category effecting the output. major categories.
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 Ishikawa-/ Fishbone diagram

Step 1 Draw the Fishbone Diagram:

– The basic diagram should be drawn by hand.

– If necessary, to keep records, the diagram should
be transferred to an electronic version or
photographed.

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 Ishikawa-/ Fishbone diagram

Step 2 List the problem/issue (output Y) to be studied in the

head of the fish.

– This is the effect portion of the diagram.

– The effect should be directly connected to the project
Y.
– Ask yourself and your team what is the effect you are
trying to control or keep from happening.

Examples:
– What is causing the part to be too thick?
– What is causing the part or the purchase order
to have a long cycle time?

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 Ishikawa-/ Fishbone diagram

Label each bone of the fish with the major categories.

Step 3
– Standard Major Categories: Measurements,
Materials, People, Environment, Methods and
Machines
– Not all categories are required on all projects.
– If the standard categories do not apply, have the
team select other categories before the exercise
begins.
– In a team environment, instead of worrying
about the format, consider labeling one flip chart
page with each of the major categories.

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 Ishikawa-/ Fishbone diagram

Brainstorm ideas to identify Level 1 and Level 2 causes

Step 4
in each category affecting the output.

– Level 1: Main causes that contribute to the effect

– Level 2: Next level of detail, causes that
contribute to the Level 1 causes.
– In a team environment, using sticky notes is a good
method to capture everyone’s ideas as to the
causes.
– Encourage the team to not only list the obvious
causes, but think about hidden or less obvious
causes.

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 Ishikawa-/ Fishbone diagram

Continue to ask why until no more useful information is

Step 5 produced. Look for causes appearing more than once.

– Give the team a set amount of time for the brainstorming

portion of the process. At the end of this time, if team
members are still working, extend the time as required.
– Once all the ideas are collected have small groups of
people work on each of the main categories in order to
organize all the ideas.
 Remove all the duplicate causes but make a note of
how many times a cause is listed. This could be an
indication of the importance of the cause.

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 Ishikawa-/ Fishbone diagram

Step 6 Review the results with the team.

– Take the information gathered from the team

meeting and create a electronic version.

– Review the final results with the team at the next

meeting.

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 Ishikawa-/ Fishbone diagram
Materials Measurement People
Buyer
Draft
Quantity
Errors
not Quality
Emphasis Training
Lack of Checklist
Quantity of
Change POs Imagemax Poor Handwriting
Effectiveness on Draft
Buyer Quantity of
No Price POs
Typist Typing
Reschedules Government
BOM Audits/ Errors
Errors Requirements
Onesy In a Hurry
Buying Tired What effects the
Time and Cost
No consistent Required for PO
We've form for COPO Processing
Batching
always done Overnight
POs
it that way Batch Process
Scanning
Level RAPIDS is not
Keep Loading User Freindly
Use of Too
Copies
Imagemax many
Too much No Word Processing
CYB Repeats or Spell Check
to Type
Don't trust iWin
System 12 Transactions
per PO Training
Not
Incorporating Familiarity
Documents
Envoironment Methods Machine

Inputs Output
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 Ishikawa-/ Fishbone diagram
Inspection Design Environment
Valve
Yield Contamination
Stack Up Work Area
Documenation Inlet
Torque Protection Fluid
Tools Materials
Safety Wire FOD Control
Calibration
Documentation
Purge Process
Rosan Fitting
(C4A&B)
Securing
Method Solenoid

Failed
Functional
Test Test
Stand
Torque
Documentation
Wrench
Fluid Technique
Technician Purge Process
Time Purity

Product Flow
Templates Documentation
Planning
Test
Training
Equipment Tools
Torque

Connectors
Man Test Mfg. Process

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 Ishikawa-/ Fishbone diagram

Simple Fishbone used on a SQEC board by

Autonomous Team members
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 Summary

 This is a team activity, the interactive brainstorming is an important part of this

tool.
 Be sure to constitute a group with the right competencies regarding the treated
problem
 Remember that a fishbone identifies the potential causes, not symptoms, therefore
look for causes not for solutions
 A fishbone:
 Helps the team concentrate on the content of the problem
 Provides a snapshot of the team’s collective knowledge
 Helps build a team consensus regarding the root causes of the problem
 Do not accept results as a fact – validate.
 Be suspicious of diagrams with few factors, or which are neat and well ordered

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