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