Solving Complex Industrial Problems without Statistics

166 Pages·2016·5.38 MB·English

by  Pawlak, Ralph R

Solving
Complex Industrial
Problems without
Statistics
TThhiiss ppaaggee iinntteennttiioonnaallllyy lleefftt bbllaannkk
Solving
Complex Industrial
Problems without
Statistics
Ralph R. Pawlak
CRC Press
Taylor & Francis Group
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Version Date: 20151104
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To Rose:
My high school sweetheart who became
my lifelong love as my wife.
TThhiiss ppaaggee iinntteennttiioonnaallllyy lleefftt bbllaannkk
Contents
Preface .................................................................................................................xi
Acknowledgments .........................................................................................xiii
About the Author .............................................................................................xv
Introduction ...................................................................................................xvii
Chapter 1 A different approach ..................................................................1
1.1 Visual observation ...................................................................................1
1.2 Concept sketches ......................................................................................4
1.3 Clue uniqueness .......................................................................................6
1.4 Comparison of twin sets .........................................................................7
1.5 Group twin set comparison ...................................................................9
1.6 Data ranking ...........................................................................................11
1.7 Fractional analysis .................................................................................12
1.8 Simple analysis .......................................................................................14
1.9 Summary ................................................................................................15
Chapter 2 Assembly problem ....................................................................17
2.1 Flywheel bolt assembly .........................................................................17
2.2 Summary ................................................................................................24
Chapter 3 Faulty thinking ..........................................................................27
3.1 Individual differences ...........................................................................27
3.2 Individual action has consequences ...................................................28
3.3 Combustible components .....................................................................28
3.4 Data collection ........................................................................................29
3.5 Clues to the cause ..................................................................................30
3.6 Summary ................................................................................................30
Chapter 4 Batch mixing problem ..............................................................33
4.1 Process problems ...................................................................................33
4.2 Steps in the process ...............................................................................34
4.3 Problem occurrence ...............................................................................34
vii
viii Contents
4.4 Investigation findings ...........................................................................36
4.5 Summary ................................................................................................37
Chapter 5 Component assembly ...............................................................39
5.1 Operator skill and knowledge .............................................................39
5.2 Plan of attack ..........................................................................................40
5.3 Findings ..................................................................................................41
5.4 Establishing a visual guide ..................................................................42
5.5 Summary ................................................................................................42
Chapter 6 Assigning responsibility .........................................................45
6.1 Creating identification ..........................................................................45
6.2 Problem description ..............................................................................45
6.3 Specific problem .....................................................................................46
6.4 Proposed solution ..................................................................................47
6.5 Summary ................................................................................................48
Chapter 7 Electrical components ..............................................................49
7.1 View of the problem ..............................................................................49
7.2 View of the defect ..................................................................................51
7.3 Plan of attack ..........................................................................................52
7.4 Review of job instructions ....................................................................52
7.5 Problem control ......................................................................................53
7.6 Summary ................................................................................................56
Chapter 8 New process development .......................................................59
8.1 New process initiation ..........................................................................59
8.2 Rationale for improvement ..................................................................59
8.3 Lack of operating instructions .............................................................60
8.4 Process conception ................................................................................62
8.5 Initial runout ..........................................................................................63
8.6 Lack of system knowledge ...................................................................64
8.7 Developing an operation plan .............................................................65
8.8 Unswerving work application .............................................................67
8.9 Summary ................................................................................................69
Chapter 9 Innovative solutions .................................................................71
9.1 Surface contact temperature ................................................................71
9.2 Reductions in force ................................................................................76
9.3 Battery charging area ............................................................................77
9.4 Moving assembly problem ...................................................................79
9.5 Summary ................................................................................................82
Contents ix
Chapter 10 Electronic chip wafer ................................................................85
10.1 Following the job routing .....................................................................85
10.2 Summary ................................................................................................89
Chapter 11 Machining problem ..................................................................93
11.1 Machining evaluation ...........................................................................93
11.2 Create a ranking system .......................................................................99
11.3 Create a sketch .....................................................................................101
11.4 Present result data ...............................................................................101
11.5 Recap of machining .............................................................................102
11.6 Another example .................................................................................103
11.7 Summary ..............................................................................................105
Chapter 12 Systemic chaos .........................................................................107
12.1 Truck head processing ........................................................................107
12.2 Background information ....................................................................108
12.3 Dissimilar testing devices ..................................................................109
12.4 Observations ..........................................................................................110
12.5 Problem cause .......................................................................................113
12.6 Summary ...............................................................................................114
Chapter 13 Sequester and shutdown ........................................................117
13.1 Notification of sequester ......................................................................117
13.2 Measurement system ..........................................................................120
13.3 Measurement rationale .......................................................................120
13.4 Component measurement ..................................................................122
13.5 Data evaluation ....................................................................................122
13.6 Conclusion ............................................................................................125
13.7 Summary ..............................................................................................127
Chapter 14 Corroboration of results .........................................................129
14.1 Verification ............................................................................................129
14.2 Simple charts ........................................................................................129
14.3 Judge five before against five after ....................................................130
14.4 Comparison of twin sets .....................................................................131
14.5 Summary ..............................................................................................132
Chapter 15 Summary ...................................................................................135
Appendix: Glossary of terms .......................................................................139
Index .................................................................................................................141