EQUIPMENT PERFORMANCE

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.

4. Determine the interval class width by one of two methods:

A. Width = Range/# Intervals = 8.1 / 10 = 0.81

B. Divide the Standard Deviation by three. In this case, the height data has a Standard Deviation of
1.85, which yields a class interval size of 0.62 inches, and therefore a total of 14 class intervals (Range
of 8.1 divided by 0.62, rounded up). This is slightly more class intervals than our rule of thumb
indicated.

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

BENEFITS OF USING A FISHBONE

DIAGRAM
Step 1 - Identify and Define the Effect
• Decide on the effect to examine
• Use Operational Definitions

STEPS FOR CONSTRUCTING AND

ANALYZING FISHBONE DIAGRAM
Step 2 - Fill in the Effect Box and Draw the Spine

Iron in
Product

STEPS FOR CONSTRUCTING AND

ANALYZING FISHBONE DIAGRAM
Step 3 - Identify Main Categories
Manpower Material Method

Iron in
Product

Measurement Mother Nature Machine

STEPS FOR CONSTRUCTING AND

ANALYZING ISHIKAWA DIAGRAM
 Step 4 - Identify Causes Influencing the Effect
- For each major branch, identify other specific factors which may be the CAUSES of
the EFFECT
Manpower Material Method
Maintenance Raw materials Analytical procedure

Inexperienced

analyst Sampling
Lab solvent contamination
Iron in
Lab error Rust near sample
Product
Materials for construction
points
Rusty pipes

Solvent contamination Exchanger leak

Measurement Mother Nature Machine

STEPS FOR CONSTRUCTING AND

ANALYZING FISHBONE DIAGRAM
 Step 5 - Add Detailed Levels
Identify increasingly more detailed levels of causes and continue organizing them
under related causes or categories. You can do this by asking a series of why
questions.
Manpower Material Method
Maintenance Raw materials Analytical procedure
Iron tools Supplier Calibration

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

Solvent contamination Exchanger leak

Measurement Mother Nature Machine

STEPS FOR CONSTRUCTING AND

ANALYZING FISHBONE DIAGRAM
Step 6 - Analyze the diagram
Analysis helps you identify causes that warrant further investigation.
Since Cause-and-Effect Diagrams identify only possible causes, you
may want to use a Pareto Chart to help your team determine the
cause to focus on first.

STEPS FOR CONSTRUCTING AND

ANALYZING FISHBONE DIAGRAM
  originated in 1897 when an Italian economist named
Vilfredo Pareto created a formula representing the
uneven distribution of wealth - what later came to be
known as the 80-20 rule.
 a method of identifying the vital few causes (typically
20%) that can answer most of the (typically 80%)
problems.
 Dr. J. M. Juran started applying this principal to defect
analysis - separating the "vital few" from the "trivial many",
and called it the "Pareto Chart".

 a method of organizing errors, problems, or defects to

help focus problem-solving efforts.

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.

 Using this graphical technique

you can determine the extent to
which one variable seems “to
follow” another. (If one increases
, does the other increase?)

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:

 When trying to identify potential root causes of problems.

 After brainstorming causes and effects using a fishbone diagram, to
determine objectively whether a particular cause and effect are related.
 When determining whether two effects that appear to be related both
occur with the same cause.
 When testing for autocorrelation before constructing a control chart.

WHEN TO USE SCATTER DIAGRAM?

Possible correlations between variables:

WHEN TO USE SCATTER DIAGRAM?

 Trend Analysis is the practice of collecting information and
attempting to spot a pattern, or trend, in the information.

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.

 Teams use FMEA to evaluate processes for possible failures and to

prevent them by correcting the processes proactively rather than
reacting to adverse events after failures have occurred.

FAILURE MODE AND EFFECT ANALYSIS

 RPN method is used to evaluate the risk associated with the potential
problems identified through the FMEA.

 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

 Calculate the RPN by obtaining the product of the three ratings:

 RPN = Severity x Occurrence x Detection

RISK PRIORITY NUMBER (RPN)

 Here is an example of a simplified FMEA for a seat belt
installation process at an automobile assembly plant.

FAILURE MODE AND EFFECT ANALYSIS

 "Failure Mode & Effects Analysis (FMEA)." MoreSteam.
https://www.moresteam.com/toolbox/fmea.cfm.
 "Scatter Diagram." ASQ. http://asq.org/learn-about-
quality/cause-analysis-tools/overview/scatter.html.
 Mobley, Higgins, and Wikoff. Maintenance Engineering
Handbook. 7th ed. McGraw-Hill.

REFERENCES