Solving Complex Industrial Problems without Statistics

Presenting: Problem Solving Sans Statistics Enhance your problem-solving skills, and improve your company’s profitability using the methods outlined in Solving Complex Industrial Problems without Statistics. Introducing a process that involves working through problems and solutions without relying on complicated statistical design or analysis, this book pulls away from data-driven thinking and provides the problem solver with a new way of solving problems. Utilizing techniques that have been applied in facilities throughout the U.S., Canada, Italy, China, and Hong Kong, it demonstrates the use of process and problem differences and similarities, and provides a better understanding of analogous comparisons. The book incorporates visual analysis tools and problem examples in a format that facilitates comprehension and learning, presents novel concepts that do not require numbers or statistics, and provides a better understanding of the solution system/process overall. Each chapter presents new information, as well as case studies that include: Different problem situations Short histories detailing the operation, condition, and circumstances that were present at the time of each study Photographs, sketches, or tables with simple explanations to describe the circumstances, conditions, and the actions taken Methods of solution in rudimentary form Chapter summaries to review important mechanisms and workings Final summaries to tie together the important methods and techniques that facilitate easy problem solutions Solving Complex Industrial Problems without Statistics provides valuable insight into the solution of complex quality and manufacturing problems, without the use of statistics, and is essential to anyone involved in quality, control, problem-solving activities, or total quality management. Content: A Different ApproachVisual ObservationConcept SketchesClue UniquenessComparison of Twin SetsGroup Twin Set ComparisonData RankingFractional AnalysisSimple AnalysisSummaryAssembly ProblemFlywheel Bolt AssemblySummaryFaulty ThinkingIndividual DifferencesIndividual Action Has ConsequencesCombustible ComponentsData CollectionClues to the CauseSummaryBatch Mixing ProblemProcess ProblemsSteps in the ProcessProblem OccurrenceInvestigation FindingsSummaryComponent AssemblyOperator Skill and KnowledgePlan of AttackFindingsEstablishing a Visual GuideSummaryAssigning ResponsibilityCreating IdentificationProblem DescriptionSpecific ProblemProposed SolutionSummaryElectrical ComponentsView of the ProblemView of the DefectPlan of AttackReview of Job InstructionsProblem ControlSummaryNew Process DevelopmentNew Process InitiationRationale for ImprovementLack of Operating InstructionsProcess ConceptionInitial RunoutLack of System KnowledgeDeveloping an Operation PlanUnswerving Work ApplicationSummaryInnovative SolutionsSurface Contact TemperatureReductions in ForceBattery Charging AreaMoving Assembly ProblemSummaryElectronic Chip WaferFollowing the Job RoutingSummaryMachining ProblemMachining EvaluationCreate a Ranking SystemCreate a SketchPresent Result DataRecap of MachiningAnother ExampleSummarySystemic ChaosTruck Head ProcessingBackground InformationDissimilar Testing DevicesObservationsProblem CauseSummarySequester and ShutdownNotification of SequesterMeasurement SystemMeasurement RationaleComponent MeasurementData EvaluationConclusionSummaryCorroboration of ResultsVerificationSimple ChartsJudge Five Before Against Five AfterComparison of Twin SetsSummaryAppendix: Glossary of Terms Front Cover 1 Dedication 6 Contents 8 Preface 12 Acknowledgments 14 About the Author 16 Introduction 18 Chapter One: A different approach 26 Chapter Two: Assembly problem 42 Chapter Three: Faulty thinking 52 Chapter Four: Batch mixing problem 58 Chapter Five: Component assembly 64 Chapter Six: Assigning responsibility 70 Chapter Seven: Electrical components 74 Chapter Eight: New process development 84 Chapter Nine: Innovative solutions 96 Chapter Ten: Electronic chip wafer 110 Chapter Eleven: Machining problem 118 Chapter Twelve: Systemic chaos 132 Chapter Thirteen: Sequester and shutdown 142 Chapter Fourteen: Corroboration of results 154 Chapter Fifteen: Summary 160 Appendix: Glossary of terms 164 Back Cover 166 Chapter 1. A different approach -- chapter 2. Assembly problem -- chapter 3. Faulty thinking -- chapter 4. Batch mixing process -- chapter 5. Component assembly -- chapter 6. Assigning responsibility -- chapter 7. Electrical components -- chapter 8. New process development -- chapter 9. Innovative solutions -- chapter 10. Electronic chip wafer -- chapter 11. Machining problem -- chapter 12. Systemic chaos -- chapter 13. Sequester and shutdown -- chapter 14. Corroboration of results -- chapter 15. Summary Enhance your problem-solving skills, and improve your company's profitability using the methods outlined in this book. Introducing a process that involves working through problems and solutions without relying on complicated statistical design or analysis, this book pulls away from data-driven thinking and provides the problem solver with a new way of solving problems