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PROBLEM SOLVING TOOLS

FLOW CHART
BRAIN STORMING
CAUSE AND EFFECT DIAGRAM
DATA COLLECTION
GRAPHS AND CHARTS
STRATIFICATION
PARETO ANALYSIS
HISTOGRAM
SCATTER DIAGRAM
BOX AND WHISKER

FLOW CHART

A flow diagram is a graphic

representation of sequence of steps
that we perform same output. The
output may be a physical product, a
service, information or a
combination of the three.

Process

Arrow

Manual Operation

Connector

Decision Box

Document / Record Extended Process

Manual Input

FLOW CHART

Develop a common understanding of an overall

process.
Uncover potential problems, bottle necks
unnecessary steps and rework loops in the process.
Guide the potential solution without having to
observe the process physically.

Interpretation
Better understanding of the current process, as a
whole, and common understanding.
Estimation of cost of Quality.
Develop plans for data gathering.
Generate theories about root causes.
Discuss ways to stratify the data for analysis, to
identify root cause.
Identify the need to streamline the process or
changes in the process.
Provide training on how the process should
operate.

EXCERCISE
Draw a Flow Chart for following process : Rework of Non Conforming product.
Disposition of Non Conforming In-coming
material.

Cause Effect
Basic to quality improvement is the need
to identify the root cause of a problem. The
cause effect diagram is an effective way to
organize and display the various theories about
what those root cause might be.
Man

Material

Method

Effect

Machine Measurement Environment

Cause Effect
Visual Representation and Interrelationship among
the possible factors and effect.
(Aspect Impact Sheet)
Strength
Focuses the the attention of all people in the team
on the specific problem at hand in a structured and
systematic way.
Encourage innovative thinking.
C-E diagram has a tremendous capability of
communicating to others.

Cause Effect
Step how to construct :1. Define clearly the effect.
2. Draw a arrow (thicker) and place the effect at the arrow.
3. Use brain storming or a rational step- by-step approach
to identify the possible causes.
4. Each of the major cause placed and joined with central
spine at 70 deg. Angle.
5. Add causes for each main area and subsidiary cause till
you reach at root cause.
6. Check the logical validity of each cause chain.
7. Check the completeness.

EXCERCISE
Draw a Cause and Effect Diagram for following effects : Mixing of Arm rear brake stopper
Reducing Water Generation.

Stratification
Stratification is the separation of data into
categories. Its most fragment use is during the
diagnostic to identify categories contribute to
the problem being solved.
Stratification Variable :The Characteristic used to separate the
data is called a stratification variable.

Stratification
Point out exactly the root cause.
Interpretation

Which area needs further

investigation

1. Usually present the stratification results in bar

chart .
2. If no category stands out, look at another variable.
Within each category of first variable.
Pitfalls and Traps :1. Conclude too much.
2. Small difference / May be random error.

Exercise :If a team is solving a problem for which no data exist,

there is no point in making a list of variables or
characteristics to be used in stratifying data.
When a stratification does not indicate an obvious
pattern, the exercise has been a waste of time.
Stratification is a tool which applies well only to
relatively simple situations with a limited number of
variables.
Stratification applies to situations dealing with
methods and procedures as well as with technology.

When to Stratify :
1. Identifying Projects COQ./COPQ
2. Analyzing Symptoms.
3. Testing theories.
Steps :1 Select the Stratification variable.
2 Establish Category for each variable.
3 Sort the observation.
4 Display

Pareto Analysis
Pareto Analysis is a ranked comparison of
factor related to a quality problem. It helps a
quality improvement project teams to identify
and focus on the VITAL few factors.
Vilfredo (1848-1923)
M.O. Lorenz

Vital few useful many.

Number Percent
Item of Errors of Total
G
44
29
J
38
25
M
31
21
Q
16
11
B
8
5
D
5
3
C
3
2
A
1
1
O
1
1
R
1
1
N
1
1
L
1
1
I
0
0
E
0
0
H
0
0
K
0
0
F
0
0
P
0
0
Total
150

Cumulative
Percent of
Total
29
55
75
86
91
95
97
97
98
99
99
100
100
100
100
100
100
100

Awkward Zone.

120 Vital
Break Point
few
100
80
60
Useful
40
Many
20
0
G J MQ B D C A O R N L I E H K F P

100
80
60
40
20
0

If a Pareto analysis does not shows a clear cut

break point usually takes the following approach :1. Identify the those few contributor which counts for
about 60% of the total effect.
2. Call these vital few and begin the diagnostic
journey.
3. Once you find a some path and improve repeat the
Pareto, the contributor that were in awkward Zone
may now be among the vital few.
4. Repeat 1-3.

When to use Pareto :1. Prioritizing Problems.

2. Analyzing Symptoms.
3. Proving Effectiveness of remedy.

Misapplication :Objective data rather then opinion.

BOX and WHISKER PLOT

Box plots like histogram, provide a
graphic summary of the patterns of
variation in a set of data.
The box plot is especially useful when
working with small sets of data or
comparing many different
distribution.

BOX and WHISKER PLOT

HIGHEST VALUE
THIRD QUARTILE
MEDIAN
FIRST QUARTILE
LOWEST VALUE

BOX and WHISKER PLOT

Contractor 1
A
45
B
102

2
183
125

Response time in minutes

3
4
5
6
7
207 226 243 251 268
145 156 188 192 215

Min
min
First Quartile ((1)n+2) / 4
Median
(n+1)/2
Third Quartile ((3)n+2) / 4
Max
max

Contractor
A
B
45
102
207
145
247
190
272
228
345
279

8
272
228

9
290
251

10
345
279

 Median response time of B is

better than A.

400

Variability of A is high than B

300

Even though the A had

shortest response time only
about 25% of As response
time were less than 207,
while 75% of Bs were less
than 228min.

200

100

Nearly 25% of As response

times were longer than Bs
longest response time.
B

Comparing Patterns of variations

Differences in the location of the
MEDIAN.
Differences in the amount of the
variation.
The presence or absence of outliers.
Symmetry or asymmetry in the data.

BOX PLOT Vs HISTOGRAM

Box plot indicates about the width of
variation and the presence of various forms
of asymmetry.
Whereas, Histogram provides information
about distribution of data along with width
of variation and central tendency.

BOX PLOT Vs HISTOGRAM

Potential Pitfalls and problems in

interpretation
Current condition true data representation .
More than 40 points - good enough.
Just help you / lead you to establish a
THEORY, which needs further confirmation.