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Industrial Problem Solving Simplified: An 8-Step Program

Book Description

Industrial Problem Solving Simplified provides a roadmap for solving manufacturing problems. Containing numerous examples of actual problems and their solutions in various industrial environments, it is for novice as well as experienced manufacturing owners, managers, quality representatives, consultants, trainers, and procurement professionals.

Author Ralph Pawlak's roadmap is a proven system that has been used to eliminate major manufacturing problems in electronics, casting, blow molding, and assembly operations. What's more, it has been used effectively in the manufacture of toys, juvenile products, chemicals, automotive engines, and innumerable components of many manufacturing facilities—and in the U.S., Canada, China, and Europe. The book's insights into problem causes and the methods to solve them once and for all are applicable to most problems in most industries.

Pawlak, with decades of experience as manager of manufacturing, quality, and plant engineering for General Motors, Fisher Price, Vibratech, and others, offers tools to solve problems and shows how to use them. You'll learn how to use tools like quality check sheets, flow diagrams, concept sheets, duo diagrams, variation plots, sketches, sum-of-extremes tests, good versus bad comparisons, fractionals with interactions, and many-level checks. What's more, these are tools anyone can put to good use today. No special knowledge of statistics, or advanced math or engineering, is required. If you can add, subtract, multiply, and divide—and use your eyes and ears—you can learn to solve industrial problems like a pro.

This book will help you:

  1. Clarify the conditions that cause problems

  2. Define the cause of problems

  3. Generate clues as to the causes of problems and their solutions

  4. Collect accurate and relevant data

  5. Use specific tools to solve problems effectively

  6. Establish consistent work processes to ensure problems do not return

Industrial Problem Solving Simplified will empower you and your people not just to solve manufacturing problems but optimize processes, improve productivity, and save money. With the plans, examples, and worksheets in this book, you will become a proficient problem solver.

What you'll learn

  • How to determine problem causes

  • How to identify defects

  • How to manage the problem and its solution through data collection and clue generation

  • How to use simple analysis tools

  • How to establish a consistent work process to maintain improvements after the problem is solved

Who this book is for

Owners, managers, line workers, quality controllers, consultants, trainers, purchasing agents, and others in any company that has manufacturing facilities in house or outsourced.

Table of Contents

  1. Title Page
  2. Apress Business: The Unbiased Source of Business Information
  3. Dedication
  4. Contents
  5. Preface
  6. About the Author
  7. Acknowledgments
  8. Introduction
  9. CHAPTER 1: Define the Problem
    1. The Cause and Why It Is Important
    2. Problems: Inherent in Manufacturing
    3. Key to Gleaning Clues and Solving Problems
    4. Summary
  10. CHAPTER 2: Define Fault Characteristics
    1. Defects: Clues to a Problem’s Cause
    2. Start with Conditional Data
    3. Collect Quantifiable Data
    4. Summary
  11. CHAPTER 3: Construct a Concept Sheet
    1. Enter the Concept Sheet
    2. Poor Fusion Weld Concept Sheet
    3. Front Cover Oil Leak Concept Sheet
    4. Leaks Concept Sheet
    5. Failure Concept Sheet
    6. Bent Ignition Coil Connector Pins
    7. A Focus on Process: Engine Assembly Routing
    8. PCB Board Process Map
    9. Summary
  12. CHAPTER 4: Develop a Plan of Attack
    1. Use Your Concept Sheet
    2. A Simple Plan of Attack
    3. Evaluation Considerations
    4. Photographs of Seal Conditions
    5. Simple Tools Work Well
    6. Acceptable and Unacceptable Thrust Bearings
    7. Prevention
    8. Summary
  13. CHAPTER 5: Collect Relevant Data
    1. Use the Problem Sheet to Gather Data
    2. Collect Variable Data
    3. Collecting Attribute Data
    4. Visual Evaluation System
    5. Summary
  14. CHAPTER 6: Generate Clues
    1. Define the Problem
    2. Verify the Process
    3. Develop an Assessment Plan
    4. Conduct Checks
    5. React to the Problem
    6. Example Manufacture Design
    7. Guidelines for Clue Collection
    8. Identify and Sequester Bad Parts
    9. Use a Defect Diagram
    10. Summary
  15. CHAPTER 7: Choose and Use Analysis Tools
    1. Six Prime Problem-Solving Tools
    2. Basic Analysis
    3. Trait Peculiarities
    4. Sum of Extremes Test
    5. Comparison of Individuals in Duos (Sets of Two Units)
    6. Comparison of Individuals in Groups
    7. Group Data Applications
    8. Fractional Analysis
    9. Tests for Clue Generation or Verification
    10. Summary
  16. CHAPTER 8: Use Innovative Analysis Tools
    1. Visual Observation
    2. Lot Identification Flowcharts
    3. Sound Problems
    4. Cracked or Broken Problem Sheet
    5. Summary
  17. CHAPTER 9: Establish Consistent Work, Many-Level Reviews, and Certification
    1. Consistent Work
    2. Many-Level Reviews
    3. Certify Problem Solutions and Verify
    4. Case Study: The Value of Comparisons
    5. Summary
  18. CHAPTER 10: Summary
  19. APPENDIX A: Fractional Explained
  20. APPENDIX B: Interaction Explained
    1. Stuffing Example
    2. Stripped-Threads Example
    3. Balance Shaft Assembly Noise
  21. APPENDIX C: Cracked-or-Broken Example
  22. APPENDIX D: Torque-to-Turn Example
  23. APPENDIX E: Sum of Extremes Test
  24. APPENDIX F: Definitions
  25. Index