PROBLEM-SOLVING

TOOLS
 Exploratory Tools
• Pareto Analysis
• Fish Diagrams
• Gantt Chart
• PERT Chart
• Job / Worksite Analysis Guide
 Pareto Analysis
• Items identified and ordered on common scale in
decreasing frequency, creating a cumulative
distribution
• 80/20 Rule: 20% of the items account for 80% of
the problems
• Allows the company to concentrate resources on
the jobs with the most problems
 Pareto Analysis

20

80

80

20

Causes Problems
 Pareto Analysis
• Example Diagram
 Pareto Analysis

220 100% 220

200 90% 200
180 80% 180 200%

Prosentase Kumulatif
Prosentase Kumulatif

Frekuensi Kumulatif
Frekuensi Kumulatif

160 70% 160

140
60%
140 150%
120 120
50%
100 80
100
40% 100%
80 80
58 30%
60 42 42 60
40 20% 40 31 24 50%
19 16
20 10% 20
0 0% 0 0%
1 2 3 4 1 2 3 4
 Fishbone Diagrams
• Cause-and-effect diagrams
• Identified problem or undesirable result is
the “head”
• Contributing factors are the “bones”
• Typical categories include: Human,
machine, methods, materials,
environment, and administrative
• Estimates associated probabilities
Fishbone Diagrams
 Gantt Chart
• Used for planning of complex projects
• Shows expected start and completion
times, also duration of events
• Similarly, major events can be broken into
smaller sub-tasks
• Shade the bars to show actual completion
time
Gantt Chart
 PERT Chart
• Program Evaluation and Review Technique
(PERT) is a planning and control tool
• Also known as Network Diagram or Critical
Path
• Graphically portrays the optimum way to
obtain a desired objective with respects to
time
• Optimistic, average, and pessimistic time
estimates utilized
PERT Chart
 Job / Worksite
Analysis Guide
• Perform a walkthrough observing the area,
worker, task, environment, administrative
constraints, etc.
• Develop an overall perspective of the
situation
• Particularly useful in workstation redesign
Job / Worksite Analysis Guide
 Recording and
Analysis Tools
• Operation Process Chart
• Flow Process Chart
• Flow Diagram
• Worker and Machine Process Charts
• Gang Process Charts
 Operation Process
Chart
• Chronological sequence of all operations,
inspections, time allowances, materials
• Depicts entrance and exit of all
components and sub-assemblies and
products
• Provides information on the number of
employees required time for jobs and
inspections
Basic Symbols

process symbol
Operation

transportation

Delay
Inspection
Storage
Operation Process Chart
Operation
Process Chart
 Flow Process Chart
• More detailed, fit for closer observation
of smaller components or assemblies
• Shows all moves (distances) and storage
delays (times) for product movement in
plant
• Aids in the reduction of hidden costs,
“Muda.”
• Can be beneficial for plant layout
suggestions
 Types of
Flow Process Chart

• Product/material
• Operative/person
Flow Process
Chart
Flow Process
Chart
 Flow Diagram
• Pictorial representation of the layout
of the plant
• Good supplement to the Flow Process
Chart
 Flow Diagram

1 2 3 4
5
PRODUKSI GUDANG
Flow Diagram
 Worker and Machine
Process Charts
• Used to study, analyze, and improve one
workstation
• Shows the time relationship between working
cycle of the person and the operating cycle of
the machine
• Reveals idle time for both machines and workers
Worker and Machine Process
Chart
Definisi dan Kegunaan

Menggambarkan hubungan waktu
antara working cycle seseorang
dengan operating cycle suatu mesin

membandingkan idle mesin dengan
idle pekerja
 Worker and Machine
Process Chart
Contoh:
man Machine 1 Machine 2

loading loading

walking
press
loading loading

idle
walking
press
Worker and Machine Process
Chart

l+m
N1 ≤
l+ w
N = jumlah mesin
m = total machine running time
w = walking time
l = loading and unloading time
Worker and Machine Process
Chart
• total expected cost (TEC)

(l + m)( K1 + N 1 K 2 )
TEC N1 =
N1

TEC N 2 = (l + w)( K1 + N 2 K 2 )

K1 = operator rate
K2 = cost of machine
Worker and Machine Process
Chart
• contoh soal
proses Time
(minute)
Pick up plate into press dies 0,1
Lubricate dies in press 0,3
Press 1,2
Walk to next press 0,1
$ worker (K1) = $ 12 / hour
$ machine (K2) = $ 10 / hour
Worker and Machine Process
Chart
• Ditanya:
• Jumlah mesin yang dibutuhkan
• TEC tiap kemungkinan jumlah mesin
 Jawaban
• N = (l+m)/(l+w) = (0.4+1.2)/
(0.4+0.1) = 3.2
• Sehingga jumlah mesin yang
mungkin adalah 3 atau 4 mesin
 Jawaban
• TEC3 = (l+m)(K1+n1K2)/n1
= (0.4+1.2)(12+3 x 10)/3/60
= $ 0.3733/ unit

• TEC4 = (l+w)(K1+n2K2)
= (0.4+0.1)(12+4x 10)/60
= $ 0.4333 /unit
Gang Process Chart
 Quantitative Tools
• Synchronous Servicing
• Random Servicing
• Line Balancing
 Synchronous
Servicing
• Assigning more than one machine
to an operator seldom results in ideal case where
both the worker and the machine are occupied
during the whole cycle.
n=l+m
l
n = Number of machine the operator is assigned
l = Total operator loading and unloading
(servicing) time per machine
m = Totalmachine running time (automatic
power feed).
 Synchronous
Servicing
• Example: assume a total cycle time of
four minutes to produce aproduct, as
measured from the start of the
unloading of the previously completed
product to the end of the machine cycle
time. Operator servicing, which includes
both the unloading of the completed
product and the loading of the raw
materials is one minute,while the cycle
time of the automatic machince cycle is
three minutes.
 Synchronous
Answer:
Servicing
n = l + m = 1 + 3 = 4 machines
l 1

Worker 1
Machine 1

Machine 2

Machine 3
Machine 4

Legend: Worker Working

Loading/unloading
Machine running

Idle Time
 Random Servicing
• Helps to determine the number of machines to
assign to an operator when it is not known
exactly when each machine needs to be serviced
or for how long
• The binomial expansion give a useful
approximation of the machine down probability
 Random Servicing
• Assuming that each machine is down at
random times during the day and that
the probability of the down time is p
and the probability of runtime is q = (1-
p). Each term of the binomial expansion
can be expressed as a probability of m
(out of n) machines down:
P(m of n) = n! pm qn-m
m! (n-m)!
 Line Balancing
• Helps to determine the ideal number of
workers to be assigned to a production line
• Computer software is available to eliminate
the calculations

E = Eficiency
SM = Standard minute per operation
AM = Allowed standard minutes per operation
 Definisi
Line balancing merupakan suatu metode
penugasan sejumlah pekerjaan yang
saling berkaitan dalam satu lini produksi
sehingga setiap stasiun kerja memiliki
waktu yang tidak melebihi waktu siklus
dari stasiun kerja tersebut.
Line balancing berusaha menyeimbangkan
seluruh lintasan yang ada dalam lini
perakitan sehingga aliran produksi
berjalan lancar.
How to Calculate Line Efficiency ?
Standard Minutes
Operator to Perform
Operation
1 0.49
2 0.31
3 0.25
4 0.44
5 0.54 Operator 4

Operator 3

Operator 5

Operator 1
Operator 2
 Line Efficiency ?
Standard Minutes Allowed
Wait Time Based on
Operator to Perform Standard
Slowest Operator
Operation Minutes
1 0.49 0.05 0.54
2 0.31 0.23 0.54
3 0.25 0.29 0.54
4 0.44 0.1 0.54
5 0.54 0 0.54

2.03 2.7

∑ S.M .
1
E= 5
X 100
∑ A.M
1
Opportunities for Improvements ?
Standard Minutes Allowed
Wait Time Based on
Operator to Perform Standard
Slowest Operator
Operation Minutes
1 0.49 0.05 0.54
2 0.31 0.23 0.54
3 0.25 0.29 0.54
4 0.44 0.1 0.54
5 0.54 0 0.54

2.03 2.7

Efficiency 75.19%

0.44

0.25 0.54

0.49
0.31
 Assembly Line
(7 operations)
Operation Standard Minutes
1 1.5
2 2.25
3 1.25
4 2.5
5 3
6 2.75
7 1.75
Desired Rate of Production = 1000/day
Efficiency = 95%
1 day = 10 hours = 600 minutes
Thus R = 1000/600 = 1.67 units/minute

Numbers of Operator Needed

in Assembly Line?
N = R × ∑ AM =R ×
∑ SM
Operation Standard Minutes
E
1 1.5
2 2.25
3 1.25
4 2.5
5 3
6 2.75
7 1.75

minutes/unit 0.6

∑SM 15
R 1.67
E 0.95

26.36842105

27 operators
 1.5/0.6

Output? 2.25/0.6
Dst.

(standard
Operation Standard Minutes minutes)/(minutes/u Operators
nit)
1 1.5 2.5 3
2 2.25 3.75 4
3 1.25 2.083333333 2
4 2.5 4.166666667 5
5 3 5 5
6 2.75 4.583333333 5
7 1.75 2.916666667 3

minutes/unit 0.6 600/1000 27

 Slowest One? (2.5/3)*0.6
(3.75/4)*0.6
Dst.
(standard
Operation Standard Minutes minutes)/(minutes/u Operators
nit)
1 1.5 2.5 3 0.5
2 2.25 3.75 4 0.5625
3 1.25 2.083333333 2 0.625
4 2.5 4.166666667 5 0.5
5 3 5 5 0.6
6 2.75 4.583333333 5 0.55
7 1.75 2.916666667 3 0.583333333

5 × 60
output = = 100 / hour = 1000 / day
3
 Line Balancing Problem
3.4 mins

2.2 mins E
2.7 mins
A
C
4.1mins

D F G
1.7mins 3.3 mins 2.6 mins
 Question
• 1. What process is the bottleneck?
• 2. How much is the maximum
production per hour?
• 3. How much the efficiency?
• 4. How to minimize work stations?
• 5. How should they be grouped?
• 6. New efficiency?
• A. 73.2%
• B. 56.7%
Calculate efficiency
3.4 mins
• C. 69.7%
• D. 79.6% B

• E. 81.2%
2.2 mins E
2.7 mins
A
C
4.1mins

D F G
1.7mins 3.3 mins 2.6 mins
(2.2+3.4+4.1+2.7+1.7+3.3+2.6)
4.1x7

20
28.7

69.7%

1-69.7%=30.3% Balance Delay

Number of Workstation
tc

tt
NNNN

∑ ( )
ay

ii
=
sc

mm
(bottleneck)
kl e

ee

20
= 4.88 work stations
s

4.1
 4 Stations 20/24=83.3%

Line Balancing Solution

(5.6) Max prod./hour
3.4 60/6
Station 3 10 units/hour
Station 1 B

E
2.2
2.7
A C
(6.0)
4.1
Station 2
Station 4

(5.8) D F G
1.7 3.3 2.6
All under 6 minutes?
 5 Stations
Line Balancing Problem
3.4 mins
5.6 20/5.6x5 = 20/28 = 71.4%
B

2.2 mins E
2.7 mins
A
C
4.1mins

Max Prod./hour D F G
60/5.6 1.7mins 3.3 mins 2.6 mins
10.7 units/hour
5.0
 What is the minimum # of work stations?
Round down.
40 secs

59 secs

34 secs
84 secs
• 3
• 2
• 4
• 5 56 secs
• 6 45 secs
 ∑ (task times )
N=
cycle time
40+59+84+56+34+45 = 318

318/84 = 3.78 or 3 work stations

What is the efficiency with 6 operators?

Efficency (% ) =
∑ (task times) (100)
(number of stations)(cycle time)
318/6 x 84=
318/504 =
63%
 99 secs 3 Stations ?

40 secs
118 secs
59 secs

34 secs
84 secs

318/3x118 56 secs 45 secs

318/354 = 89.8%

101 secs

Efficency (% ) =
∑ (task times) (100)
(number of stations)(cycle time)
 99 secs 4 Stations?

40 secs
84 secs
79 secs
59 secs

34 secs
84 secs

318/4 x 99 = 56 secs 45 secs

318/396 = 80.3%

56 secs